Glycerol levulinate ketals and their use in the manufacture of polyurethanes, and polyurethanes formed therefrom

ABSTRACT

The present disclosure relates to the preparation of ketal compounds from glycerol and levulinic acid and esters, and uses thereof, in particular the manufacture of polyurethanes.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 13/184,064, filed on Jul. 15, 2011, now allowed,which is a divisional application of U.S. patent application Ser. No.11/915,549, filed May 6, 2008, now U.S. Pat. No. 8,053,468, issued onNov. 8, 2011 which claims the benefits of International PatentApplication PCT/US2006/045200, filed Nov. 22, 2006, and U.S. ProvisionalPatent Application No. 60/738,988 filed on Nov. 22, 2005, all of theforegoing being incorporated by reference in their entirety herein.

TECHNICAL FIELD

The present disclosure relates to the preparation of ketal compoundsfrom glycerol and levulinic acid and esters.

BACKGROUND

Many known chemical products such as surfactants, plasticizers,solvents, and polymers are currently manufactured from non-renewable,expensive, petroleum-derived or natural gas-derived feedstock compounds.High raw material costs and uncertainty of future supplies requires thediscovery and development of surfactants, plasticizers, solvents, andpolymers that can be made from inexpensive renewable biomass-derivedfeedstocks and by simple chemical methods. Glycerol is an inexpensiverenewable compound that is readily available as a by-product ofbiodiesel production or via fermentation of carbohydrates. Levulinic(4-oxopentanoic) acid is another abundant feedstock that is prepared onan industrial scale by acidic degradation of hexoses andhexose-containing polysaccharides such as cellulose, starch, sucrose,and the like. Chemical products produced from these two materials couldfill a need for inexpensive, renewable consumer and industrial products.

SUMMARY

Provided herein are ketal compounds prepared from glycerol and levulinicacid or derivatives thereof. In certain embodiments, such ketalcompounds can have the formula:

wherein R¹ is hydrogen or a carbon atom of a levulinate fragment; R² ishydroxyl, an oxygen atom of glycerol, or an oxygen atom of an esterifiedglycerol fragment; and p is an integer. Compounds of this formulationcan be prepared through the reaction of glycerol, or a glycerolderivative having the formula:

wherein R⁴ and R⁵ are independently selected from the group consistingof hydrogen; linear, branched, or cyclic alkyl; linear, branched, orcyclic alkenyl; aryl, and arylalkyl; and a levulinic acid, levulinicester, angelicalactone, or a dialkyl ketal of levulinic ester. Thereaction can be effected in the presence of an acid catalyst, and underconditions sufficient to provide for removal of water from the reactionmixture.

In another embodiment, a ketal compound can have the formula:

wherein R⁹ is hydrogen or a carboxyl moiety; R¹⁰is OR¹¹, or N(R¹²)₂; R¹¹and R¹² are independently hydrogen or a linear, branched, or cyclicalkyl; and p is an integer. This compound can be combined with amonohydric alcohol or carboxylic ester, and a reaction can be effectedin the presence of a base catalyst.

An example of a product resulting from such a reaction can include:

wherein R³ is hydrogen; methyl; linear, branched, or cyclic alkyl;linear, branched, or cyclic alkenyl; aryl, aralkyl, and alkyloxyalkyl;and X is selected from hydrogen or

wherein R⁶ is selected from hydrogen; linear, branched, or cyclic alkyl;linear, branched or cyclic alkenyl; aryl; aralkyl; and alkyloxyalkyl. Insome embodiments, it is preferred that R³ is selected from a C₃-C₃₀linear, branched, or cyclic alkyl; linear, branched, or cyclic alkenyl;aralkyl; and alkyloxyalkyl. In another embodiment, when R³ is hydrogen,the reaction product can be present as a salt. Suitable salts caninclude alkali, alkali-earth, ammonia, and amine salts.

In another embodiment, the compound having formula:

wherein R⁹ is hydrogen or a carboxyl moiety; R¹⁰ is OR¹¹, or N(R¹²)₂;R¹¹ and R¹² are independently hydrogen or a linear, branched, or cyclicalkyl; and p is an integer, can undergo a reaction in the presence of atrans-esterification catalyst. Examples of compounds resulting from sucha reaction can include:

In a further embodiment, compounds can be prepared which have theformula:

wherein R³ is hydrogen; methyl; linear, branched, or cyclic alkyl;linear, branched, or cyclic alkenyl; aryl, aralkyl, and alkyloxyalkyl;and Y is selected from the group consisting of:

wherein one of R⁷ or R⁸ is hydrogen and the other is a C₁-C₃₀ linearalkyl; one of A or B is hydrogen and the other is an ester; and m and nare independently integers from 0 to 20, wherein the sum of m+n is inthe range from 8 to 21. In some embodiments, it is preferred that R³ isselected from C₃-C₃₀ linear, branched, or cyclic alkyl; linear,branched, or cyclic alkenyl; aralkyl; and alkyloxyalkyl. In anotherembodiment, R⁷ or R⁸ is a C₆-C₃₀ linear alkyl, or preferably a C₆-C₁₄linear alkyl. In certain embodiments, when R³ is hydrogen, the compoundscan be present as a salt. Suitable salts can include alkali,alkali-earth, ammonia, and amine salts.

Any of the compounds above can optionally be isolated or prepared ineither the cis or the trans confirmation. In some cases, the compoundscan be predominantly in the cis configuration, i.e., the substitutedoxymethylene moiety attached to the dioxolane ring is predominantly inthe cis configuration relative to the configuration of the side chainbearing the carboxyl group. Preferably, the compounds are isolated orprepared exclusively in the cis configuration. Alternatively, thecompounds can be isolated or prepared in predominantly the transconfiguration, i.e., the substituted oxymethylene moiety attached to thedioxolane ring is predominantly in the trans configuration relative tothe configuration of the side chain bearing the carboxyl group. Asabove, the compounds are preferably isolated or prepared exclusively inthe trans configuration.

Also provided herein is a polymeric compound comprising a unit havingthe formula:

wherein q is an integer.

This polymer, and any of the compounds described above, can be combinedwith a base polymer to form a plasticized polymer composition. Examplesof base polymers can include vinyl chloride polymer,poly(3-hydroxyalkanoate)polymer, poly(lactate)polymer, andpolysaccharide polymer.

The details of one or more embodiments of the invention are set forth inthe description below. Other features, objects, and advantages of theinvention will be apparent from the description and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the figures, which are exemplary embodiments:

FIG. 1 is a mass spectrum of a stereoisomer prepared according toExample 2;

FIG. 2 is a mass spectrum of another stereoisomer prepared according toExample 2;

FIG. 3 is a mass spectrum of a lactone ketal prepared according toExample 4; and

FIG. 4 is a mass spectrum of a compound prepared according to Example29.

DETAILED DESCRIPTION

The present disclosure provides a series of glycerol-derived compoundsthat are based on the formation of a ketal with the ketone group oflevulinic acid. Glycerol-levulinate ketal compounds can be produced byreacting approximately one molar equivalent of glycerol withapproximately one molar equivalent of levulinic acid in the presence ofan acid catalyst, and under conditions allowing for removal of water,typically by distillation. The reaction is preferably carried out usingbetween 0.7 to 1.3 molar equivalents of levulinic acid, although thereaction can be carried out with lower or higher amounts of levulinicacid. However, when the amount of levulinic acid is too low, much of theglycerol remains unreacted. Alternatively, if the amount of levulinicacid is too high, then di- and tri-levulinate esters of glycerol areformed in large quantities, thereby reducing the yield of the desiredketal adducts of glycerol and levulinate.

During the course of the reaction between one equivalent of glycerol andone equivalent of levulinate, two equivalents of water are formed. Watercan conveniently be removed by distillation, or by an azeotropicdistillation in the presence of a suitable inert solvent such as hexane,heptane, toluene, benzene, and the like. When about two equivalents ofwater have been removed from the reaction mixture, the reaction mixturecontains predominantly a polymeric levulinate-glycerol ketal adductcomprising a repeat unit having formula (1):

wherein the R¹ is hydrogen or a carboxyl atom of a levulinate fragment,and wherein R² is hydroxyl, an oxygen atom of a glycerol, or an oxygenatom of an esterified glycerol fragment, and wherein p is an integer.

The product is a polymer that is, in the absence of other compounds andimpurities, typically terminated at its ends by a levulinoyl group andby a glycerol ester fragment.

The value of p depends on may factors and may significantly vary,depending on how much water has been removed, the reactant ratio, acidcatalyst and severity of the heating conditions used to remove water.The purity of the glycerol and levulinate are also factors. Relativelyimpure industrial grades of glycerol and levulinate give adducts whereinp is in a range typically between 1 and 10. However, even with pureglycerol and levulinate it is difficult to obtain polymers with p valuessignificantly in excess of 30. It has been found that the directpolycondensation reaction between glycerol and levulinate becomesstaggered due to formation of the polymers of formula (1′), wherein R¹is represented by a gamma-valerolactone derivative, as shown herein:

If heated for sufficiently long time, the compound (1′) will slowlyrearrange to a levulinoyl-terminated polymer, thereby allowing forfurther polymer growth. However, in industrial practice, it is notpractical or necessary to rely on such long reaction times, and it ispreferred that the polycondensation reaction be stopped when about 70 to95% of the theoretical amount of water has been collected. The resultingpolymers comprise glycerol fragments that are esterified at more thanone hydroxyl group, and such fragments are recognized herein as pointsof polymer branching or points of repeat unit inversion, wherein therepeat unit is of formula (1).

Depending on the severity of the conditions of the reaction, some etherbond formation, resulting in diglyceryl fragments, or some eliminationof hydroxyl groups from glycerol, to form acrolein, is possible. It isalso possible that some angelicalactone formation from levulinate alsooccurs and this product may be isolated and re-used. Typically, thepolymeric adduct of glycerol and levulinate prepared from industrialgrade glycerol and levulinate is a very viscous, semi-transparent ortransparent liquid with a pale yellowish-brownish to near colorlesshoney-like appearance due to traces of unidentified byproducts. However,even in the presence of these by-products, the final polymeric adductcomprising the repeat unit of formula (1) is found herein to be usefulin the preparation of compounds and various intermediates.

Similarly to the free levulinic acid, levulinic esters of monohydricalkanols, beta- and gamma-angelicalactones, and 4,4-dialkoxypentanoateesters (which are esters of ketals of levulinic acid with monohydricalkanols) are also suitable to practice the synthesis of the glycerollevulinate ketal compounds comprising the repeat unit of formula (1).Any of these levulinic derivatives can be used in the synthesis of theglycerol levulinate ketal compounds in a substantially pure form, or ina mixture. The mixtures can comprise any of the above compounds with aquantity of free levulinic acid. When mixtures of the levulinicderivatives are used to make the glycerol levulinate ketal compounds, itis preferred that about one molar equivalent of these compounds is usedper molar equivalent of glycerol.

Similarly, in the synthesis of the glycerol levulinate ketal compounds,some or all of the glycerol can be replaced with a glycerol ketal oracetal of formula (2):

wherein R⁴ and R⁵ are each independently selected from hydrogen; linear,branched, or cyclic alkyl; linear, branched, or cyclic alkenyl; aryl; oraralkyl. Preferably, R⁴ and R⁵ are not both hydrogen.

Mono, di and tri esters of glycerol with simple C₁-C₈ linear or branchedalkanoic acids can also be used instead of glycerol, or in a mixturewith glycerol. Monolevulinate ester of glycerol is also a suitablestarting material.

Synthesis of the condensation polymeric glycerol levulinate ketal adductcomprising the repeat unit of formula (1) of glycerol is carried outwith glycerol and levulinic acid, which are fully miscible compounds.For industrial practice, glycerol and levulinic acid do not need to beanhydrous and thus may contain varying amounts of water. However, it ispreferred that these starting materials do not contain excessive amountsof water, as this results in a less efficient use of equipment.Typically, glycerol and levulinic acid with water contents of about 10%or less are preferred.

Synthesis of the polymeric levulinate-glycerol ketal adduct comprisingthe repeat unit of formula (1) typically requires the presence of asuitable acid catalyst. Non-limiting examples of such catalysts includestrong mineral acids, such as sulfuric, hydrochloric, hydrofluoroboric,hydrobromic acids, p-toluenesulfonic acid, camphorosulfonic acid,methanesulfonic acid, and like. Various resins that contain protonatedsulfonic acid groups are also useful as they can be easily recoveredafter completion of the reaction. Examples of acids also include Lewisacids. For example, boron trifluoride and various complexes of BF₃,exemplified by BF₃ diethyl etherate. Silica, acidic alumina, titania,zirconia, various acidic clays, and mixed aluminum or magnesium oxidescan be used. Activated carbon derivatives comprising mineral acid,sulfonic acid, or Lewis acid derivatives can also be used. One ofordinary skill in the art can practice many variations on the part ofthe catalyst composition and the amounts used in the preparationdescribed herein. Amount and type of catalyst depends on the specificchemical composition of the epoxide and glycerol or glycerol derivativeof formula (3), used in the reaction and can be readily established byone skilled in the art. It is preferred, however, that low-costcatalysts that impart minimal or negligible corrosion effects on theequipment used in the synthesis, and have low volatility, toxicity, andenvironmental impacts, or can be easily neutralized to innocuouscompounds, are used. Sulfuric acid is one such preferred catalyst. Thereaction of condensation of glycerol and levulinic acid can be carriedout without a catalyst, but, for industrial purposes, these reactionconditions are generally too slow to be practical. In order to yieldindustrial quantities of compounds comprising the repeat unit of formula(1), it is preferred that the condensation be accelerated by use of acatalyst and elevated temperature sufficient to remove water from thereaction mixture without undue time expenditure. The condensationreaction may optionally also be carried out under reduced pressure tofacilitate removal of water, and to minimize formation of discoloredby-products.

An adduct of glycerol and levulinate comprising ketal fragments offormula (1) can be further subjected to chemical reactions to yieldderivatives of glycerol and levulinate.

Trans-Esterification with Alcohols

Products can be obtained when polymeric compounds comprising the repeatunits of formula (1) are treated under trans-esterification conditionswith a monohydric alcohol. Typically, such reactions are carried outwith an alcohol in the presence of a base, such as alkali oralkali-earth hydroxides or alkoxides. The catalyst can be used in asoluble or insoluble form. Many trans-esterification base catalysts areknown in the art, and the present disclosure is not limited to the useof a particular catalyst.

Such trans-esterification reactions can result in the formation of amixture of cis- and trans-stereoisomers of a hydroxyester compoundhaving formula (3):

wherein R³ is a linear, branched, or cyclic alkyl or alkenyl, aryl,aralkyl, or alkyloxyalkyl.

A typical procedure for making the hydroxyester of formula (3) involvesuse of an excess of alcohol which, after neutralization of the basecatalyst, is removed by distillation. The trans-esterification reactionwith an alcohol typically also results in the formation of minorquantities of free glycerol that readily separates as analcohol-immiscible liquid from the alcoholic solutions of hydroxyester(3), ester of levulinic acid, and the R³OH alcohol used in thetrans-esterification. The latter compound can be readily separated fromthe hydroxyester of formula (3) by distillation, typically under reducedpressure, and, if desired, re-used in the synthesis of theglycerol-levulinate ketal polymeric adduct comprising the repeat unit offormula (1).

It has been found that the cis- and trans-isomers of the compound offormula (3) can be readily separated from each other by distillationusing ordinary distillation equipment known in the art, such asdistillation columns with sufficient number of plates, falling filmdistillation columns, and the like. Preferably, distillation to separatecis- and trans-isomers of the compound of formula (3) is carried outunder reduced pressure and in the relative absence of atrans-esterification catalyst. The latter condition is beneficial as itminimizes polymerization of the compound of formula (3), as well asformation of a free alcohol, R³OH, which can make maintenance ofsufficient vacuum difficult. However, the distillation may be carriedout without complete removal of trans-esterification catalyst, and anyundistilled oligomers can be recovered and re-used for preparation ofthe compound of formula (3) by the base-catalyzed reaction disclosedabove.

It has also been found that alkaline trans-esterification reaction ofketal-ester co-polymers of glycerol and levulinate comprising the repeatunits of formula (1) yield mixtures of reaction products that largelycomprise the cis and trans-isomers of the compounds of formula (1),which are 1,2-ketals of glycerol and a levulinate ester with alcoholR³OH. Only negligible traces of 1,3-glycerol ketals of esterifiedlevulinate are found in such product mixtures.

Trans-Esterification with Carboxylic Esters In a related embodiment, thetrans-esterification in the presence of base is carried out underconditions similar to that described above for an alcoholictrans-esterification, except that instead of an alcohol, an ester of acarboxylic acid and an alkanol is used. In this case, stereoisomers ofcarboxylic esters of glycerol levulinate ketal of formula (4) areformed:

wherein R³ is a linear, branched, or cyclic alkyl or alkenyl, aryl,aralkyl, or alkyloxyalkyl, and R⁶ is hydrogen, or is a linear, branched,or cyclic alkyl or alkenyl, aryl, aralkyl, alkyloxyalkyl, or oxoalkyl.

The synthesis of compound (4) using trans-esterification with thecarboxylic ester is also typically accompanied by the formation of minorquantities of levulinate ester, glycerol, glycerol mono, di and triesters of the carboxylic acid R⁶COOH, and of varying quantities of thecompound of formula (3). The quantity of the compound of formula (3)depends largely on the value of p specified in the structure of therepeat unit of formula (1) described above; polymeric ketal adductshaving lower values of p tend to produce higher relative quantities ofthe compound of formula (3) in relation to the compound of formula (4).The reaction products from base-catalyzed trans-esterification withcarboxylic esters are typically separated and purified by distillation.

De-Polymerizing Trans-Esterification of Polymeric Glycerol LevulinateKetal Adducts

In another embodiment, a polymer comprising a glycerol levulinate ketaladduct comprising a unit of formula (1a):

wherein R⁹ is hydrogen or a carboxyl moiety; R¹⁰ is OR¹¹, or N(R¹²)₂;R¹¹ and R¹² are independently hydrogen or a linear, branched, or cyclicalkyl; and p is an integer. In some embodiments, OR¹¹ can be a fragmentof a monohydric or a polyhydric alcohol. The compound comprising theunit of formula (1a) is subjected to a trans-esterification reaction,resulting in a depolymerization that provides for the formation of abicyclic lactone-ketal adduct of glycerol and levulinate, named herein“segetolide” (“lactone of a crop field”), having formula (5):

7-methyl-3,8,10-trioxabicyclo[5.2.1]decan-4-one.

A further embodiment includes the provision of a cyclic dimer ofsegetolide (5). Such a cyclic dimer (named herein “bis-segetolide”) is acyclic bis-lactone (diolide) bis-ketal having formula 5(a):

Typically, such a depolymerizing trans-esterification reaction iscarried out under substantially anhydrous reaction conditions, and inthe presence of an acid or a base catalyst. Alternatively, one or moreof many other catalysts known in the art to catalyze esterification ortrans-esterification reactions, such as those known in the art ofsynthesis of various polyesters, may be used. Numerous examples ofcatalysts for synthesizing of compounds of formulae (5) and/or (5a) bydepolymerization of polymers comprising repeat units of formula (1a) canbe found in the art of polyester synthesis. Description of suchcatalysts and methods of their use can be found, for example, in U.S.Pat. Nos. 4,133,800, 4,205,157, 4,208,527, 5,028,667, 5,095,098,5,210,108, 5,208,297, 5,202,413, 5,292,859 5,342,969, 5,565,545, and6,828,272.

Under such conditions, the cyclic ketal lactones of formulae (5) and/or5(a) are in equilibrium with one another, the polymeric compound, andvarious oligomers comprising the unit of formula (1a). Under sufficienttemperature, typically in the range of 160-300° C., and, preferably,under reduced pressure, a vapor phase comprising ketal lactones offormulae (5) and (5a) is formed. The compounds of formulae (5) and (5a)are typically separated from the reaction mixture by distillation underreduce pressure, and separated from each other, if desired, bydistillation. Further purification of the compounds of formulae (5) and(5a) can be achieved by repeated distillations, or by using a highefficiency distillation column. By adjusting the temperature andpressure of the distillation, it is possible to obtain the compound offormula (5) substantially free of the compound of formula (5a) withoutdifficulty, as these two compounds have a large difference in boilingtemperatures. It is understood that if an effective trans-esterificationcatalyst is present in the preparation of substantially pure compoundsof formula (5) and/or 5(a), such compounds may equilibrate to form amixture of these to compounds, as well as varying quantities of polymerscomprising the cis-isomers of the units of formula (1b):

wherein R⁹ is hydrogen or a carboxyl moiety; R¹⁰ is OR¹¹, or N(R¹²)₂;R¹¹ and R¹² are independently hydrogen or a linear, branched, or cyclicalkyl; and p is an integer. In some embodiments, OR¹¹ can be a fragmentof a monohydric or a polyhydric alcohol.

When depolymerization is conducted in the presence of a catalyst, usinga polymer comprising a mixture with approximately equal quantity of cis-and trans-units of formula (1), approximately half of the quantity ofthe polymeric adduct comprising the cis- and trans-isomeric units offormula (1) can be converted to the compound of formula (5). Theremainder of the undistilled polymeric adduct consists predominantly, orexclusively, of the units of formula (1) having thetrans-stereochemistry (1c):

wherein R⁹ is hydrogen or a carboxyl moiety; R¹⁰ is OR¹¹, or N(R¹²)₂;R¹¹ and R¹² are independently hydrogen or a linear, branched, or cyclicalkyl; and p is an integer. In some embodiments, OR¹¹ can be a fragmentof a monohydric or a polyhydric alcohol.

During depolymerization of polymers comprising the unit of formula (1a)conducted in the absence of an effective amount of an acid catalyst thatallows the trans-ketal to re-equilibrate to a mixture of cis- andtrans-ketals, the compounds of formulae (5) and (5a) are formed onlyfrom the cis-isomers of units of formula (1b). In general, the quantityof the products of compound of formulae (5) and (5a) that can beproduced is limited by the abundance of the cis-fragments of the formula(1b) in the polymer used for depolymerization.

When depolymerization of the polymer comprising units of formula (1) isconducted in the presence of an acid catalyst, both cis- andtrans-isomers of the units are in equilibrium, and thus both cis- andtrans-units can be converted to the compound of formula (5) and/or 5(a).It is preferred, however, that when an acid catalyst is used to conductthe depolymerization reaction, the temperatures of the reaction not beallowed to exceed 120-130° C. to avoid excessive decomposition ofglycerol to acrolein, and formation of glyceryl ethers.

After the compounds of formula (5) and/or (5a) have been substantiallyremoved by distillation, the resulting depolymerization product is auseful polymer typically comprising predominantly, or exclusively, thetrans-fragments of formula (1c). Such can be further converted, forexample, by using trans-esterification with an excess alcohol or anester in the presence of base. Under such conditions, compounds offormula (3) and (4) comprising predominantly, or exclusively, thetrans-isomers of the compounds of formula (3a) and (4a), respectively,are thus prepared:

Similarly, the bicyclic lactone ketal compounds of formula (5) and/or5(a) are readily converted by a base-catalyzed trans-esterification withan alcohol or an ester to the corresponding cis-isomers of thehydroxyester (3b) and diester (4b):

The glycerol ketal derivatives of levulinic esters of formula (3), (4),(5), and 5(a), as well as the separated individual cis- andtrans-stereoisomers (3a), (3b), (4a), and (4b), are excellent solventsfor a variety of both hydrophobic compounds (e.g., fats, oils, greases,waxes, varnishes) and many hydrophilic compounds. Compounds of formula(3), wherein R³ is a C₁-C₅ lower alkyl, are miscible with water in abroad range of concentrations. Therefore, these compounds are useful aspart of various formulations in applications such as degreasing, paintthinners, paint removal or as part of formulated adhesives. Because oftheir relatively slow evaporation under ordinary environmentalconditions (which can be controlled by selecting appropriate length ofR⁶ and R³ groups), and because of a low agreeable or negligible odor,these compounds are also useful as coalescent solvents in various latexpaints and coatings where they can be supplied to the formulation inaddition to, or instead of, typical petroleum-derived solvents such as2,2,4-trimethyl-1,3-pentanediol monoisobutyrate or diisobutyrate,ketones, and aromatic hydrocarbons.

The compounds (3) and (4), as well as any individual or mixedstereoisomers thereof, have also been found to be useful as plasticizerswith various polymers, such as poly(vinyl chloride),poly(3-hydroxyalkanoates), poly(3-hydroxybutyrate), poly(lactate), andpolysaccharides.

Poly(vinyl chloride) polymers, PVC, are homopolymers or co-polymers ofvinyl chloride. Many PVC compounds of various degree of polymerization,cross-linking nd co-polymer composition are known in the art and areproduced industrially.

Poly(3-hydroxyalkanoates), PHA, are polyester homopolymers orco-polymers of 3-hydroxyalkanoic acids. Preferably, PHA is composed oflinear 3-hydroxyalkanoic fragments having from 3 to 18 carbon atomatoms. Poly(3-hydroxybutyrate), PHB, is a homopolymer that is producedbiologically, for example by various microorganisms. A pure PHB polymeris a brittle polymer having a narrow range of processing temperatures,and it decomposes readily at temperatures that are only 20-30° C. aboveits melting temperature.

Poly(lactate), or poly(lactide), PLA, is a known polyester homopolymercomprising repeat units of lactic acid of various stereochemistry.

Polysaccharides are homopolymers and co-polymers, linear or branched,comprising hexose or pentose fragments connected via glycosyl linkages.The polysaccharides may optionally contain various additional groupssuch as acylamido groups, sulfate ester groups, carboxylic ester groups,alkyl and hydroxyalkyl ether groups and the like. Such additional groupsmay be present in polysaccharides derived from natural sources or can beartificially introduced (i.e., by acylation of cellulose). Examples ofpolysaccharides include acylated derivatives of cellulose and starch, aswell as native or acylated chitin and pectin.

Plasticizers are chemical compounds added to a base compositioncomprising one or more of the above polymers with the purpose oflowering the glass transition temperature of the polymer composition,thereby making the composition more flexible and amenable to processing,e.g., by melt extrusion or molding. Plasticizers are typically used atvarious effective concentrations, and depending on the polymer used anddesired properties of the compounded polymer formulations, plasticizerscan be used at concentrations between 1 and 80% by weight of theunplasticized polymer. It is understood that, depending on the polymerand the plasticizer used, plasticizers can also confer other changes inphysical and mechanical properties of the compounded polymer, as well aschanges in barrier properties of the compounded polymer in respect toits permeability for various gases, water, water vapor, or organiccompounds. It is also understood that one or more different plasticizerscan be used in various blends with additional compounds for thepreparation of an extrudable or moldable polymer composition. Suchadditional compounds can include various inorganic and organic fillercompounds, wood dust, reinforcing fibers, dyes, pigments, stabilizers,lubricants, anti-microbial additives, and the like.

Plasticizers are typically mixed with a polymer by mixing attemperatures that are above or below the melting point of the polymer.Plasticizers can also be introduced with a help of an optional volatilesolvent. Many variations of techniques for introducing plasticizercompounds to polymer compositions are known in the art,

For use as plasticizers, compounds of formula (3) and (4) are preferablyselected from compounds wherein R³ and R⁶ are C₁-C₂₃ linear or branchedalkyls, and preferably C₁-C₁₂. Specific choices for R³ and R⁶ depend onthe polymer selected for plasticization and on the intended propertiesand application.

The glycerol ketal levulinic adducts of formula (3), (4), and (5a) areuseful as plasticizer compounds for PVC, poly(3-hydroxyalkanoates),poly(lactate), and various polysaccharide polymers. Compounds of formula(3), (4) and (5a) are compatible with these polymers across a broadrange of concentrations. Compounds of formula (4) and (5a) are preferredfor plasticization of PVC, as plasticizers with a substantial content offree hydroxyl group are generally not desired in compounded PVC resinsdue to stability problems of the PVC resin. By selecting various R³ andR⁶ moieties in the reactants used in the synthesis of these adducts, itis also possible to fine-tune the properties of the plasticizer not onlyin respect to best plasticization properties and best compatibility, butalso in respect to the barrier properties of the resulting polymer,e.g., its permeability to moisture, gases, solvents, water leaching, andodor and stain retention. Depending on the desired properties, compoundsof formula (3), (4), and (5a) can be used at various concentrations,typically, between 5 and 80% by weight of the plasticized polymercomposition. However, in practice it is sufficient to provide 5 to 25%by weight plasticizer to achieve significant lowering of the glasstransition point and thus obtain useful polymeric compositions. Theplasticizer compounds (3), (4), and (5a) can be used as individualcompounds or as mixtures, including mixtures comprising otherplasticizers known in the art such as aromatic and aliphaticdicarboxylic esters, epoxidized triglycerides, and the like.

Synthesis of Polymeric Glycerol Levulinate Ketal Compounds from theMonomers of Formulae 3-5

The compound of formula (5) and the compounds of formulae (3) and (4),inclusive of compounds with defined cis- or trans-stereochemistry, suchas (3a), (3b), (4a), (4b), can be further polymerized to provide for avariety of co-polymer compositions of glycerol and levulinate having atleast one unit of formula (6):

wherein q is an integer.

The cyclic ketal-lactone compounds of formula (5) and (5a) areparticularly suitable for use in polymerization under ring openingliving polymerization conditions. Such conditions are well known in theart and are known to yield high molecular weight melt-processablepolymers suitable for a variety of uses in the manufacturing of variousplastics and fibers. For example, U.S. Pat. Nos. 5,028,667, 5,292,859,5,095,098, and 5,210,108 contain descriptions of catalysts and methodsof use suitable for carrying out living polymerization of variouslactones and mixtures thereof. Similarly, J. Macromolecules (2001, 34,8641-8648) contains a description of conditions and catalysts forpolymerizing dioxanones. These conditions and catalysts have been foundto be useful in the polymerization or co-polymerization of compounds offormula 5 and/or 5(a) to form perfectly alternating ketal-estercopolymers of glycerol and levulinate comprising the cis-unit of formula(1b). Such polymers are clear thermoplastic transparent polymers thatcan be obtained in a practically colorless form and can bemelt-processed, extruded, cast, and rolled to a variety of shapes.

Synthesis of polymers comprising the unit of formula (6) are not limitedto living polymerization. The hydroxyesters (3) and diesters (4) canalso be converted to useful polymers comprising at least one unit offormula (6) by a polycondensation reaction in the presence of a suitablecatalyst. The art of synthesis of various polyesters by polycondensationis old and many examples of suitable catalysts are known. It has beenfound that many known catalysts for the synthesis of polyesters can beused to make polymers comprising at least one unit of formula (6).Non-limiting examples of suitable catalysts include alkali andtransitional metal alkoxides, germanium oxide, alkali metal alkoxides,sodium, and acids. Further examples include various alkoxides oftitanium and tin (II) octanoate. Other descriptions of catalysts andmethods of their use can be found, for example, in U.S. Pat. Nos.4,133,800, 4,205,157, 4,208,527, 5,028,667, 5,095,098, 5,210,108,5,208,297, 5,202,413, 5,292,859 5,342,969, 5,565,545, 6,828,272, andreferences cited therein.

The compounds of formulae (3) and (4), inclusive of compounds withdefined cis- or trans-stereochemistry, such as (3a), (3b), (4a), and(4b), are typically polymerized in the presence of an effective quantityof a polycondensation catalyst, and under conditions allowing for theremoval of an alcohol (R³OH) or an ester (R⁶COOR³) by distillation. Forpolymerization of these compounds, it is preferred (but not necessary)that the R³OH alcohol is a primary or secondary alcohol, and it is alsopreferred that the ester of formula R⁶COOR³ and/or the alcohol R³OH thatform during polycondensation have boiling points sufficiently below theboiling point of the monomers of formula (3), (4), and/or (5) so thatthey can be removed with ease from the body of the forming polymer.

The polymerization reactions can be carried out in the presence of aninert solvent, or in a neat form. Preferred non-limiting examples ofsolvents are hydrocarbons, halogenated hydrocarbons, and ethers.

The properties of the resulting polymers differ, depending on the degreeof polymerization and the stereochemistry of the monomers used in theirsynthesis.

The ester-ketal polymers of glycerol and levulinate comprising the unitof formula (6) are useful as polymeric plasticizers with variouspolymers. For example, these polymers are used for plasticizing PVC,polyesters such as PHA, PHB, and PLA, and polysaccharides such asacylated cellulose. For plasticization of these polymers, theester-ketal polymers of glycerol are blended with unplasticized polymerstypically at elevated temperatures sufficient to melt or soften theingredient with the highest melting point, and preferably, under inertatmosphere (to minimize any decomposition of the polymer plasticized).Plasticization with these compounds can also be accomplished with theaid of a solvent that is typically removed after a homogeneous blend isobtained. Plasticized compositions may contain other additives such asstabilizers, inorganic and organic fillers, reinforcing fibers,pigments, dyes, and the like. Plasticized compositions comprising thepolymers having ester-ketal repeat units of formula (6) can be cast ormolded or extruded into films, fibers, tubing, pipes, and other objectsof various shapes that are typically used to produce various consumerand industrial products from other known plasticized compositions ofPVC, PHA, PHB, PLA, and polysaccharides.

Reaction of Glycerol Levulinate Ketal Compounds with Epoxides of NormalAlpha-Olefins

In another embodiment, the compounds of formula (3) are reacted withepoxides. Preferably, the compounds of formula (3) are esters and notfree acids or salts. The epoxides are epoxides of normal alpha-olefins(NAO) or epoxidized unsaturated fatty acid esters.

The first set of reaction products can be formed by the reaction ofcompounds of formula (3) and NAO epoxides. The resulting products have aformula (7):

wherein R³ is a linear, branched, or cyclic alkyl or alkenyl, aryl,aralkyl, or alkyloxyalkyl, and one of R⁷ or R⁸ is hydrogen and the otheris a C₆-C₃₀ linear alkyl. Preferably, a C₆-C₁₄ linear alkyl.

Compounds of formula (7) are prepared from the 1,2-epoxides of NAOhaving formula (8):

wherein R⁹ is a C₆-C₃₀ linear alkyl, and preferably, a C₆-C₁₄ linearalkyl.

The compounds of formula (8) are reacted with the compounds of formula(3) in the presence of an acid catalyst, and optionally, an inertco-solvent.

Typically, catalysts for reacting epoxides with the compound of formula(3) include various acids that are known in the art. Such conditions aregenerally applicable to the reactions of the compound of formula (3)with epoxidized unsaturated fatty acid esters. Non-limiting examples ofsuch catalysts include strong mineral acids, such as sulfuric,hydrochloric, hydrofluoroboric, hydrobromic acids, p-toluenesulfonicacid, camphorosulfonic acid, methanesulfonic acid, and like. Variousresins that contain protonated sulfonic acid groups are also useful asthey can be easily recovered after completion of the reaction. Examplesof acids also include Lewis acids. For example, boron trifluoride andvarious complexes of BF₃, exemplified by BF₃ diethyl etherate, are alsouseful. Examples of other Lewis acids include anhydrous SnCl₂, SnCl₄,TiCl₄, AlCl₃, silica, acidic alumina, titania, zirconia, various acidicclays, mixed aluminum or magnesium oxides, and the like. Activatedcarbon derivatives comprising mineral acid, sulfonic acid, or Lewis acidderivatives can also be used.

The present disclosure is not limited to a specific catalyst or anamount of catalyst. One of ordinary skill in the art can practice manyvariations on the part of the catalyst composition and the amounts usedin the preparation described herein. Elevated temperatures may be usedto accelerate the reaction with less reactive catalysts, however, thetemperature of the reaction mixture is not critical for succeeding inmaking a quantity of the glyceryl ether product, as even with lessactive catalysts the reaction still proceeds to yield the desiredcompounds. Amount and type of catalyst depends on the specific chemicalcomposition of the epoxide and of the compound of formula (3) used inthe reaction, and can be readily established by one skilled in the art.

The reaction with epoxides can be carried out in the presence of anoptional co-solvent that is inert under reaction conditions and istypically removed at the end of the reaction by distillation. Typically,it is desired to use a sufficient quantity of a co-solvent or areactant, such as the compound of formula (3), to minimize cross-linkingof the epoxides via ether bond formation. Non-limiting examples ofsuitable co-solvents include saturated hydrocarbons, ethers, andpolyethers. Typically, any excess solvent and un-reacted startingmaterial are removed after completion of the reaction by distillation atnormal or reduced pressure. It is also preferred to neutralize orotherwise remove the acid catalyst prior to distillation.

Because the compounds of formula (3) are very good solvents for NAOepoxides, the reaction between epoxide and the glycerol derivative offormula (3) can also be conveniently conducted in the excess of thelatter compound, typically at 2 to 20 times molar excess. Wheninsufficient excess of the compound (3) is used, oligomeric polyetheradducts of epoxide and the compound of formula (3) are formed.

The compounds of formula (7) are further converted by saponification tothe alkali or alkali-earth metal salts of the carboxylic acid havingformula (7a).

Saponification is typically carried out in water or water-alcoholmixtures in the presence of a sufficient amount of alkali oralkali-earth metal hydroxide or carbonate, and after removal of anyexcess of the compound of formula (3) and/or co-solvent, e.g. bydistillation under reduced pressure. The salts of the compound offormula (7a) can be stored and used in an aqueous solution, or, afterevaporation of water and any volatile co-solvents, in a substantiallyanhydrous neat form.

Reaction of Glycerol Levulinate Ketal Compounds with Epoxides ofUnsaturated Fatty Acid Esters

Another set of compounds is provided herein by using reaction of thecompound of formula (3) with epoxides of unsaturated fatty acid esters.Preferably, the compounds of formula (3) are esters and not free acidsor salts. These epoxides are prepared in the manner substantiallysimilar to the above-described methods for making compounds of formula(7) from the NAO epoxides of formula (8).

Unsaturated fatty acids mean linear monocarboxylic acids having from 10to 24 carbon atoms and at least one double bond. The double bonds can bein any position, conjugated with each other or non-conjugated, but notin allenic arrangements, and any of the double bonds can beindependently cis or trans. Preferably, unsaturated fatty acids have oneto three double bonds. Fatty acids can also be composed of a mixture ofvarious unsaturated and saturated fatty acids, for example, as in thetriglycerides of various vegetable oils, fish oils, and palm oils.

Esters of unsaturated fatty acids mean esters of the above-describedfatty acids with monohydric or with polyhydric alcohols.

Monohydric alcohols are linear or branched primary or secondary alkanolsor alkoxyalkanols having from 1 to 12 carbon atoms. Preferred examplesof alkanols are methanol, ethanol, propanol, isopropanol, butanol,secondary butanol, isobutanol, isoamyl alcohol, 2-ethylhexanol.Preferred alkoxyalkanols are primary or secondary alcohols having from 3to 12 carbon atoms, wherein a linear, branched, or cyclic alkoxy grouphaving from 1 to 8 carbon atoms is located at a vicinal position to thehydroxyl group. Such alkoxyalkanols are typically derived by opening analkyl oxirane with an alkanol. Another suitable example of analkoxyalkanol is tetrahydrofurfuryl alcohol readily accessible viahydrogenation of furfural. The most preferred are monohydric alcoholsdue to their availability, cost and satisfactory stability of theiresters.

Polyhydric alcohols are linear or branched polyhydroxylated alkaneshaving from 1 to 6 hydroxyl groups. Typical examples are ethyleneglycol, propylene 1,2- and 1,3-diols, butylene glycol isomers, glycerol,1,2,4-trihydroxybutane, pentaerythritol, xylitol, ribitol, sorbitol,mannitol, and galactitol. Polyhydric alcohols can optionally contain oneor more ether bonds, and suitable examples of such polyhydric alcoholsare isosorbide, sorbitane isomers, and diglycerol.

It is preferred that substantially all hydroxyl groups of the polyhydricalcohol are esterified with an unsaturated fatty acid group. It isunderstood that in the industrial practice it may not be practical toachieve a full esterification. It is also understood that in theindustrial practice, where mixed fatty acid compositions are used, notall of the fatty acid groups can be unsaturated and some fully saturatedfatty acid groups can be present. In fact, it is cost-advantageous touse mixtures of unsaturated and saturated fatty acid esters such aspresent in triglycerides of typical vegetable oils (e.g. soybean oil,linseed oil, canola oil, safflower oil, sunflower oil, corn oil, castoroil, their blends and the like). It is preferred, however, that themixed fatty acid esters contain predominantly unsaturated fatty acidesters. It is also preferred that a fatty acid ester with a high contentof mono-unsaturated fatty acid ester is used, such as compositions foundin high oleic canola oil. Esters of 10-undecylenic acid are alsopreferred. Another preferred starting material is a mixture of methylesters of fatty acids derived by trans-esterification of vegetable oils(e.g., of soybean oil, canola oil and other unsaturated triglyceridescommonly used in the industrial production of various biodiesel fuels).

Various unsaturated fatty acid esters can be optionally blended, mixed,partially hydrogenated, or otherwise isomerized to change position orstereochemistry of the double bonds.

Epoxidized unsaturated fatty acid ester means that at least one of thedouble bonds of the unsaturated fatty acid ester is oxidized to an epoxygroup. Such oxidations are well known in the art and can be readilyaccomplished in an industrial scale, e.g., by using hydrogen peroxideand a carboxylic acid (e.g., formate or acetate), or by the halohydrinmethod. It is preferred, however, that epoxidation of a majority or allof the double bonds present in the unsaturated fatty acid ester isaccomplished. It is understood that in practice, epoxidized fatty acidesters may contain various quantities of by-products arising fromhydrolysis or rearrangement of epoxides and from cross-linking of thefatty acid chains. Use of epoxidized fatty acid esters containing smallquantities of epoxidation by-products and epoxide decompositionby-products is fully within the scope of the present disclosure.

Ethers derived from epoxides of mono-unsaturated fatty acid esters andcompound of formula (3) have formula (9):

wherein R³ is a linear, branched, or cyclic alkyl or alkenyl, aryl,aralkyl, or alkyloxyalkyl, one of A or B is H and the other is anesterified carboxyl, and n and m are integers each having values from 0to 20, and the value of the sum of m+n is in the range from 8 to 21.

When bis-epoxides or tris-epoxides of unsaturated fatty acid estershaving epoxy groups positioned in a close proximity to each other areused, an intra-molecular epoxide opening reaction takes place, resultingin the formation of one or more ether bonds each connecting two carbonatoms of the continuous fatty acid carbon chain. Typically, such etherbonds result in the formation of a tetrahydrofuran (major) andtetrahydropyran (minor) rings. Thereby forming complex mixtures of thestereoisomers of oxygenated derivatives of unsaturated fatty acid esterscomprising pendant ether groups derived from the compound of formula(3).

For example, representative isomers of the such surfactant products froma bis epoxide derived from a di-unsaturated fatty acid having two doublebonds separated by a methylene group have formulae (10a) and (10b):

Compounds of formula (10a) and (10b) are typically formed as mixturesthat also comprise other adducts such as di(glyceryl levulinate ketal)ether adducts resulting from opening of each of the epoxy groups with adifferent molecule of the compound of formula (3), resulting inoxygenated fatty acid derivatives comprising two hydroxyl groups and twopendant ether (glyceryl levulinate ketal) groups.

Preferably, the ether adducts of epoxidized fatty acid esters are formedby the reaction of the compound of formula (3), in the presence of acatalyst, followed by the removal of any excess compound of formula (3)and any co-solvent by distillation under reduced pressure.

Alternatively, the adducts of epoxidized unsaturated fatty acid estersand compound of formula (3) can be prepared by treating epoxidizedtriglycerides with the compound of formula (3) in the presence of acatalyst. In such alternative embodiment, triglyceride polyol compoundsare formed. These compounds have free secondary hydroxyl groups and(glyceryl levulinate ketal ester) ether pendant groups attached to thefatty acid chains. Optionally, ether bonds may also be present in suchadducts and the ether bonds can connect two carbon atoms of one fattyacid chain (thereby forming a tetrahydrofuran or tetrahydropyran ring)or two different fatty acid chains.

Such adducts of glycerol, or of a ketal/acetal protected glycerol, withthe epoxidized triglycerides are typically prepared from known in theart epoxidized soybean oil, linseed oil, and the like. These adducts arefound herein to be useful to produce compounds of formulae (9), (10a),and (10b). The conversion of the triglyceride adducts to the compoundsof formulae (9), (10a), and (10b) can be accomplished by atrans-esterification reaction with a monohydric alkanol in the presenceof a catalytic amount of base. The non-limiting examples of suitablebases are hydroxides of alkali or alkali-earth metals or alkoxides ofalkali metals and alkanols.

The carboxyl group in the ether adducts of compound (3) and thehydroxylated fatty acid esters can be further subjected tosaponification to furnish a salt (typically, alkali, alkali-earth,ammonium, or amine salt of the dicarboxylic compounds having formulae(11), 12(a), and 12(b):

wherein one of E or D is hydrogen and the other is carboxyl.Alternatively, the salt compounds of formulae (11), 12(a), and 12(b) areobtained by direct saponification of the adduct of the compound offormula (3) with epoxidized triglycerides.

The carboxyl group of the compounds of formula (7a), (11), 12(a), and12(b) or of the compounds of formulae (7), (9), (10a), and (10b) canalso be amidated with a primary or a secondary alkylamine or anaminoalcohol.

The alkali metal salts, alkali-earth metal salts, amine or ammoniumsalts, and amides of the carboxylic acids of formulae (7a), (11), 12(a),and 12(b) are useful ionic mild surfactants that can be used in variousformulations.

The surfactants derived from the carboxylic acids of formulae (7a),(11), 12(a), 12(b) are stable in cold and hot aqueous solutions in abroad range of pH (e.g., pH 4 to pH 13). Their surfactant, emulsifying,and micelle-forming properties are not negatively affected by thepresence of alkali-earth metal ions in the solution. This makes themuseful in formulations intended for use in hard water.

These compounds of can be used alone or in various combinations withother surfactants, solvents, glycols, polyols, fragrances, colors,biologically-active and inert additives, enzymes, and wetting agentsthat constitute the base compositions of preparations used in cleaning,dishwashing, laundry, cosmetic and personal care products, degreasingpreparations, and the like. Effective concentrations for use of thesurfactant compounds of compounds derived from the carboxylic acids ofthe formulae (7a), (11), 12(a), and 12(b) depend on the intended use ofthe formulation and can be easily established empirically by one ofordinary skills in the art. The effective concentrations for thesecompounds typically range from 0.001% to 100% of the formulated product.

It has also been found that compounds of formulae (7), (9a), (10a),(10b), and the adduct of the compound of formula (3) with epoxidizedtriglycerides are also useful as plasticizers for PVC, polyesters suchas PHA, PHB, PLA, and polysaccharides.

Co-Polymers of Glycerol Levulinate Ketals with Other Monomers

In another embodiment, glycerol ketal monomers selected from compoundshaving formulae (3), (4), (5) and (5a), and any stereoisomers thereof,can be used in the synthesis of co-polymers with a variety of othermonomers known in the art. It has been found that copolymers comprisingthe ketal repeat units of formula (1a) have a broad range of physicalproperties, and can be prepared through a condensation ortrans-esterification reaction of the monomers of formulae (3), (4), (5),and (5a) with one or more compounds selected from various polyhydricalcohols, di and tri-carboxylic acids, hydroxyacids, and cyclic esters.

Non-limiting examples of useful polyhydric alcohols include dihydricalcohols of linear or branched alkanes having from 2 to 20 carbon atoms,glycerol, diglycerol, isosorbide, sorbitol, xylitol, erythritol,pentaerythritol, trimethylolethane, trimethylol propane, diethyleneglycol, neopentyl glycol, polyethers such as hydroxyl-terminatedpoly(ethyleneoxide), poly(propyleneoxide), and the like.

Examples of suitable dicarboxylic acids include either free acids, loweralkyl esters, or anhydrides of succinic acid, maleic acid, adipic acid,isomers of phthalic acids, trimellitic acid, citric acid, itaconic acid,and isomers of naphthalene dicarboxylic acid.

Examples of hydroxyacids and esters thereof can also be used asco-polymers, and can include lactic acid, glycolic acid,3-hydroxypropionic acid, and 3-hydroxyalkanoic acids.

Hydroxyacids can be further exemplified by hydroxylated derivatives offatty acids and esters thereof, including triglycerides. Suchhydroxylated fatty acid esters including polyhydric hydroxyl derivativesknown in the art have been obtained, for example, by reacting epoxidizedfatty acid esters with one or more compounds having a hydroxyl group,wherein one or more of the oxirane groups is subjected to an epoxideopening reaction.

Suitable hydroxyacids can be further exemplified by hydroxylatedaromatic carboxylic acids such as hydroxylated benzoic acids, toluicacids, naphthoic acids, cinnamic acids, ferrulic acid, and the like.

Lactide, glycolide, 1,4-dioxan-2-ones, alkylated 1,4-dioxan-2-ones,epsilon-caprolactone, and 1,4-dioxepan-2-ones are suitable non-limitingexamples of cyclic esters.

Among other suitable co-monomers for making co-polymers of glycerollevulinate ketals comprising the repeating units of formula (1a) includecompounds of formulae (7), (9), (10a), (10b), and also, compounds offormula (7b):

wherein R³ is a linear, branched, or cyclic alkyl or alkenyl, aryl,aralkyl, or alkyloxyalkyl, and one of R⁷ or R⁸ is H and the other ishydrogen or a C₁-C₃₀ linear alkyl.

Compounds of formula (7b), compounds with linear alkyls of shorter than6 carbon atoms can be prepared by reacting compounds of formula (3) withcorresponding linear alkyl epoxides in a way substantially similar tothat described above for the preparation of the compound (7). Conditionsfor the reaction of a compound of formula (3) with volatile epoxidessuch as propylene oxide and ethylene oxide, include conducting thereaction under pressure.

Co-polymer preparation from the monomers of formulae (3), (4), (5), and(5a) and one or more compounds selected from polyhydric alcohols, di andtri-carboxylic acids, hydroxyacids, and cyclic esters can beaccomplished by using one or more of the catalysts and conditionsdescribed above for the preparation of homopolymers comprising therepeating unit of formula (1a). The resulting co-polymers can beterminated with either hydroxyls or esterified carboxyls. Polymers canbe linear, branched, star-shaped, or cross-linked, and can be randomco-polymers, block copolymers, graft copolymers, or any combinationthereof.

Of particular interest and utility are the hydroxyl terminated polymersand co-polymers comprising the repeating units of formula (1a). Suchcompounds have been found to be useful for making polyurethane polymerswith widely varying properties.

Many polyurethane polymers and methods of their preparation are known inthe art. Polyurethane polymers are compounds of exceptional industrialutility; they find numerous applications because the final properties ofthe resulting polymer can be influenced greatly through selection ofactive hydrogen monomers (typically, polyhydroxyl compounds) andisocyanates used, and by selecting the conditions used to prepare thefinished polymer products.

Many of the polymers comprising the repeating unit of formula (6) areuseful for making polyurethane polymers. For use in polyurethanesynthesis, a polymer comprising the repeating unit of formula (6) can beprepared in a hydroxyl-terminated form, wherein two or more hydroxylgroups are present on average per representative polymer structure. Thisis typically accomplished by carrying out the polymerization reactionwith at least one monomer selected from the stereoisomers of compoundsof formula (3), (4), (5), and (5a) in the presence a sufficient amountof a co-polymer polyhydric alcohol having two or more hydroxyl groups,so that polymerization product has preferably an average molecularweight in excess of 500 Da, more preferably, in excess of 1000 Da, andhas two or more hydroxyl groups, The resulting polymerization productcomprising the unit of formula (6) can be a linear, branched,cross-linked, or star-shaped polymer. One or more of such polymerizationproduct comprising the unit of formula (6) can then be used as polyolcompounds in a reaction with one or more isocyanate compounds having twoor more isocyanate groups. Many suitable isocyanate compounds are knownin the art of polyurethane synthesis. Non-limiting examples ofisocyanate compounds include diisocyanate compounds such as tolylenediisocyanate isomers, hexamethylene diisocyanate, pentamethylenediisocyanate, isophorone diisocyanate, 4,4′-methylenebis(phenylisocyanate), and the like. Further non-limiting examples of isocyanatecompounds include polyisocyanate compounds, and can be obtained byreacting one of the above diisocyanate compounds with a polyhydricalcohol or a polyhydric amine. Non-limiting examples of suitablepolyisocyanate compounds also include adducts of one or morediisocyanate compounds obtained by reacting one or more of thepolyhydric products comprising the repeating unit of formula (6) underconditions sufficient to cause reaction between the hydroxyl group andan isocyanate group. It has been found that such polyisocyanatecompounds can be obtained by mixing appropriate quantities of variousaliphatic and/or aromatic diisocyanate compounds with a polyhydricalcohol comprising the repeating units of formula (6), and causingreaction to occur by means of heating and/or with catalysts sufficientto accelerate the reaction. Non-limiting examples of typical catalystssuitable for making the polyisocyanate compounds include dibutyl tindilaurate, 1,4-diazabicyclo[2.2.2]octane (DABCO™, TED), and the like.The reaction of making a polyisocyanate compound from a polyhydricalcohol comprising the units of formula (6) can be carried out in thepresence of an inert solvent, which may optionally be removed at the endof the reaction by distillation.

One or more of the polyhydric alcohols comprising a repeating unit offormula (6) can then be reacted with one or more isocyanate compoundshaving two or more isocyanate groups per representative molecule,thereby providing for a polyurethane polymer comprising one or moreunits of formula (6) per representative polymer molecule.

Such reactions occur readily under conditions typically known to thosein the art of polyurethane synthesis, and include use of one or morecatalysts known in the art and/or elevated temperatures. Non-limitingrepresentative examples of typical catalysts include dibutyl tindilaurate and DABCO. Elevated temperatures expedite formation of thedesired polyurethane polymer, and typically, temperatures between 30 and160° C. are sufficient to commence and accelerate the reaction. Thereaction can be conducted at temperatures outside of the specifiedrange, however, at lower temperatures, the reactions may be quite slow,while at higher temperatures, side reactions and partial polymerdecomposition may occur. In general, preparation of polyurethanepolymers comprising repeat units of formula (6) is an exothermicreaction and is successful without additional heating. Synthesis ofpolyurethane polymer comprising units of formula (6) is preferablycarried out under substantially anhydrous conditions. If smallquantities of water are present, the product is typically a foam polymercomprising both urethane and urea linkages. If a foam polymer isdesired, the reaction is carried out using one more inert propellantcompounds known in the art.

Various polyurethane polymers comprising units of formula (6) can thusbe prepared and used to manufacture a plethora of polyurethane goodsthat in a way substantially similar to polyurethane polymers known inthe art. Polyurethane polymers comprising the units of formula (6) canbe solid or viscous liquids, rigid or flexible, and they can be preparedas thermoset or thermoplastic polymers. Depending on the specificpolymer composition, they can be cast, extruded, or otherwise shaped ina variety of forms needed to manufacture finished polymer goods. Thepolyurethane polymers comprising units of formula (6) can containvarious additives known in the art, such organic or inorganic fillers,pigments, stabilizers, anti-oxidants, and lubricants

The polyurethane polymers disclosed herein are made with use of low-costrenewable monomers to provide the predominant part of the weight of theresulting polymers, thereby offering a cost advantage when compared tothe known in the art polyurethanes made predominantly or exclusivelywith use of non-renewable petroleum- or coal-derived monomers.

The polyurethane polymers comprising units of formula (6) are alsorecyclable at the monomer level. If so desired, at the end of theiruseful life, the polyurethane polymers comprising the units of formula(6) can be treated by a trans-esterification reaction, to allow for thedecomposition of the polymers and the formation of one or more monomersof formulae (3), (4), (5), and (5a), which can be recovered, purifiedand re-used.

EXAMPLES Example 1

36 g of levulinic acid of 98% purity, 28 g of glycerol of 99% purity,0.08 ml of concentrated sulfuric acid, and 60 ml of n-heptane werestirred in a round bottom flask equipped with a Dean-Starks adapter. Thewhole was brought to reflux by means of heating in an oil bath, and wasrefluxed for approximately 36 hours or until about 11 ml of water wascollected in the trap of the adapter. The reaction mixture wasneutralized by the addition of 0.2 g of calcium carbonate. The heptanewas removed, and reaction mixture cooled, yielding approximately 53.2 gof a very viscous, pale-brownish, honey-like polymeric adduct thatcomprised compounds having structural repeating units of formula (1).

Example 2

20.3 g of the polymeric adduct prepared in Example 1 was dissolved in 80ml of methanol containing 0.4 g of sodium methoxide. The resultingsolution was stirred at room temperature, allowing for small quantitiesof free glycerol to separate on the bottom and on the walls of thereaction flask. The solution was filtered through a fiberglass woolplug, neutralized by vigorous stirring for 30 min with 2 g of anhydrouspotassium dihydrogen phosphate, diluted with 100 ml of methyl tert-butylether (MTBE), and dried over anhydrous sodium sulfate. The solution wasthen filtered. MTBE and excess methanol were removed under reducepressure, yielding 23.1 g of clear, slightly yellowish, practicallyodorless liquid that was analyzed by gas chromatography-massspectrometry (GC-MS). The liquid was found to contain about 15% methyllevulinate and about 82% of the stereoisomers of the compound havingformula (14):

The stereoisomers of the compound of formula (14) were detected as twopartially separable peaks on the GC chromatogram having approximatelysimilar integration areas. The peaks had the following representativemass-spectra.

A mass-spectrum of one of the stereoisomers of the compound of formula(14) eluting with a retention time of approximately 15.06 minutes isshown in FIG. 1.

A mass-spectrum of another stereoisomer of the compound of formula (14)eluting with a retention time of approximately 15.24 minutes is shown inFIG. 2.

The resulting liquid mixture of products was also found to contain about3% of the stereoisomers of diglyceryl ether levulinate ketals dimethylesters of the formula (15):

Example 3

5 g of the reaction product obtained in Example 1 were mixed with 20 mlof ethyl acetate and 0.2 g of potassium t-butoxide. The whole wasstirred for about 45 min, and complete dissolution of the polymericstarting material was observed. The reaction mixture was neutralized bystirring with 2 g of anhydrous potassium dihydrogen phosphate for about1 hr, dried over anhydrous sodium sulfate, filtered, and the excessethyl acetate was evaporated under reduced pressure. The resulting oily,transparent, pale-yellowish liquid (6.2 g) was analyzed by GC-MS and wasfound to contain approximately 14% of ethyl levulinate, approximately25% of hydroxyester isomers of formula (16):

and approximately 55% of the stereoisomers of di-ester of formula (17):

Small quantities of the stereoisomers of compound (18) were alsopresent:

Example 4

5 g of polymeric adduct prepared according to Example 1, and 0.2 g ofpotassium t-butoxide were stirred at 120-125° C. under vacuum (1 mm, 2hr), and about 1 ml of clear distillate was collected. The distillatewas analyzed by GC-MS and was found to contain predominantly the lactoneketal of formula (5). The compound of formula (5) had a representativeelectron ionization mass-spectrum shown in FIG. 3.

Example 5

10 ml of the hydroxyester of formula (14) obtained in Example 2 washeated with stirring under vacuum (6 mm, 80° C., 4 hours) until ethyllevulinate was substantially removed, as tested by GC-MS. The resultingliquid was mixed with 2 g of decene-1,2-oxide of 94% purity (Vicolox® 10brand, Arkema Group), and a complete dissolution of epoxide was observedat room temperature. 0.025 ml of boron trifluoride diethyl etherate wasintroduced into the stirred reaction mixture and an exothermic reactionwas observed with the temperature rising briefly to about 50° C. Thereaction mixture was stirred for 20 min and an aliquot was taken forGC-MS analysis. The analysis showed complete conversion of the epoxideto several stereoisomers of the hydroxyester ketal compounds of formula(19a) and (19b).

Example 6

The synthesis was carried out according to Example 5, except 2 g ofoctadecene-1,2-epoxide of 85% purity was used. The reaction productsobtained had formulae (20a) and (20b):

Example 7-8

Excess solvent from the reaction mixtures of Examples 5 and 6 wereevaporated under reduced pressure (0.5mm, 150° C.) to give neat mixturesof compounds (19a), (19b) (Example 7) or compounds (20a), (20b) (Example8). 10 ml of water was added to the resulting product mixtures, and theesters were saponified with slight excess of 0.1 N aqueous NaOH to givethe corresponding sodium salts in aqueous solution. These solutions hademulsifying and surfactant properties that were not affected by thepresence of 1 g/L calcium chloride or magnesium chloride.

Example 9

Levulinic acid (98% purity, 697.3 g), glycerol (99% purity, 554.2 g),concentrated sulfuric acid (0.25 g), and a stirring bar were placed in aweighted 2-liter round-bottom evaporating flask, and the whole was setto rotate at 100 rpm on a rotary evaporator equipped with an efficientvertical condenser cooled to 4° C., and a vacuum was applied using avacuum pump capable of providing an eventual vacuum of 6 mm. The flaskwas rotated and heated using an oil bath with an initial temperaturesetting of 80° C. A rapid distillation of water was observed. Afterapproximately 130 ml of water was collected in a receiving flask, thebath temperature was increased to 115° C., and distillation of water wascontinued until the rate of distillation had decreased to approximatelyless than 1 mL per 15 min. The bath temperature than was then increasedto 150° C., and the reaction mixture was heated under a 0.2 mm vacuumfor 1 hour. The reaction was then stopped, and the temperature of thereaction product was allowed to equilibrate to room temperature. Theresulting polymerization product (1054.3 g) at room temperature was aviscous, slightly brownish, sticky, syrup-like liquid, and waspractically insoluble in cold water.

The catalyst was then neutralized by adding 2 grams of dry sodiumbicarbonate, and by stirring the content of the flask on a rotaryevaporator at 100° C. for 2 hours, while a 6 mm vacuum was applied. Theneutralized reaction product was allowed to cool to room temperature,and any insoluble inorganic matter was allowed to settle. The resultingviscous liquid co-polymer was stored at room temperature, and was usedin subsequent examples in a decanted or filtered form.

The resulting product was predominantly a polymer comprising therepeating unit of formula (1).

Example 10

Levulinic acid (98% purity, 696.1 g), glycerol (99.5% purity, 607.5 g),concentrated sulfuric acid (1.0 g), and a stirring bar were placed in aweighted 2-liter round-bottom evaporating flask, and the whole was setto rotate at 100 rpm on a rotary evaporator equipped with an efficientvertical condenser cooled at 4° C., and a vacuum was applied using avacuum pump capable of providing an eventual vacuum of 6 mm. The flaskwas rotated and heated using an oil bath with an initial temperaturesetting of 80° C. A rapid distillation of water was observed. Afterapproximately 110 ml of water was collected in a receiving flask, thebath temperature was increased to 110° C., and distillation of water wascontinued until the rate of distillation had decreased to approximatelyless than 1 mL per 60 min (this took approximately 5 hours). Thereaction was then stopped, and the temperature of the reaction productwas allowed to equilibrate to room temperature. The resultingpolymerization product (1087 g) at room temperature was a viscous,practically colorless, sticky syrup-like liquid sparingly soluble incold water.

The resulting product was predominantly a polymer comprising therepeating unit of formula (1).

Example 11

Levulinic acid (98% purity, 700.1 g), glycerol (99.0% purity, 607.4 g),concentrated sulfuric acid (0.4 g), and a stirring bar were placed in aweighted 2-liter round-bottom evaporating flask, and the whole was setto rotate at 100 rpm on a rotary evaporator equipped with an efficientvertical condenser cooled at 4° C., and a vacuum was applied using avacuum pump capable of providing an eventual vacuum of 6 mm. The flaskwas rotated and heated using an oil bath with an initial temperaturesetting of 80° C. A rapid distillation of water was observed. Afterapproximately 130 ml of water was collected in a receiving flask, thebath temperature was increased to 105° C., and distillation of water wascontinued until it had practically subsided (approximately 6 hours). Thereaction was then stopped, and the temperature of the reaction productwas allowed to equilibrate to room temperature. The resultingpolymerization product (1097 g) at room temperature was a viscous,practically colorless, sticky, syrup-like liquid sparingly soluble incold water.

The resulting product was predominantly a polymer comprising therepeating unit of formula (1).

Example 12

A mixture 1.05 mol of triacetyl glycerol, 2.1 mol of glycerol, 1.96 molof solketal, 2.65 mol of ethyl levulinate, 1.7 mol of levulinic acid,0.4 mol of alpha-angelica lactone and 0.2 ml of concentrated sulfuricacid was magnetically stirred and heated under nitrogen to 100-105° C.in a round bottom flask equipped with a water-cooled condenser.Distillation of a mixture of acetone, ethanol, water, acetic acid andethyl acetate was observed. Heating with stirring was continued untilthe distillation had practically subsided (about 16 hours). Theresulting viscous, transparent, slightly yellowish liquid was pouredinto a 2 L evaporation flask, and the whole was heated on a rotaryevaporator to 110-115° C. at a reduced pressure using a vacuum pumpcapable of providing an eventual vacuum of 6 mm. After distillation ofthe water and volatiles has subsided (approximately 6 hours), theresulting viscous polymerization product (939 g) was cooled down to roomtemperature.

The resulting product was predominantly a polymer comprising therepeating unit of formula (1).

Example 13

A mixture of 1.02 mol of glycerol, 2.95 mol of levulinic acid and 0.2 gof sulfuric acid was heated on a rotary evaporator to 80-90° C. at areduced pressure a vacuum pump capable of providing an eventual vacuumof 6 mm, until distillation of water had practically subsided. Theresulting product (385 g) was a mixture of ester products comprisingpredominantly trilevulinoyl glycerol and 1,2-dilevulinoyl glycerol.

Example 14

The synthesis was carried out according to Example 11, except that thestarting reaction mixture additionally contained 40.2 grams of a mixtureof glyceryl esters prepared according to example 13. The resultingproduct (1139 g) was a glycerol-branched polymer comprising therepeating unit of formula (1).

Example 15

The synthesis was carried out according to Example 14, except the addedamount of ester prepared according to the Example 14 was 82.2 g. Theresulting polymer (1226 g) was a glycerol-branched polymer comprisingthe repeating unit of formula (1).

Example 16

1021 g of the polymeric product comprising the repeating unit of formula(1) prepared according to Example 11 was slowly poured (over period of 1hour) into a stirred reactor containing 1.2 liters of a methanolicsolution containing 6 grams of sodium methoxide. After stirring at roomtemperature for 8 hours, the content of the reactor were collected, andthe methanol was evaporated at reduced pressure using a rotaryevaporator. The resulting yellowish-orange liquid was transferred to aseparatory funnel and thoroughly mixed with 0.8 L of tert-butyl methylether. The contents were allowed to stand for 4 hours and separate intotwo layers. The lower level containing primarily glycerol, sodium saltof compound (3), wherein R³ is H, and small quantities of sodiumlevulinate, was discarded, and the upper layer was stripped of thetert-butyl methyl ether using a rotary evaporator. The resultingslightly yellowish liquid (992 g) was analyzed by GC-MS and was found tocontain approximately 12% of methyl levulinate, approximately 80% of thecompound of formula (3), wherein R³ is methyl, as a mixture ofapproximately equal amounts of cis- and trans-isomers, and smallquantities of the compound of formula (5) and stereoisomers of compoundshaving formulae (21) and (22) (ca. 1% each):

The resulting mixture of stereoisomers of compound of formula (3) wasfurther purified by removal of methyl levulinate at a reduced pressure,and then further purified by distillation using a falling film columnunder 0.5-1 millibar vacuum and a temperature set at 130° C. Theresidual undistilled compounds 21 and 22 were collected and treated withmethanol containing 0.2% sodium methoxide, to yield a 20:80 mixture ofmethyl levulinate and the compound of formula (3).

Example 17

The reaction was carried out according to Example 16, except thatethanol was used in the reaction instead of methanol, and the startingpolymeric product (732 g) was prepared according to Example 12. Theresulting product was analyzed by GC-MS and was found to containapproximately 9% of ethyl levulinate and 88% of the compound of formula(3), wherein R³ is methyl, as a mixture of approximately equal amountsof cis- and trans-isomers. The compound of formula (3) was then furtherpurified by distilling out ethyl levulinate at a reduced pressure.

Example 18

301.2 g of the polymer prepared according to Example 9 were stirred with500 ml of n-butanol containing 6 grams of sodium hydroxide at roomtemperature for 24 hours. The resulting transparent yellowish solutionwas stripped of excess n-butanol on a rotary evaporator under reducedpressure, and the whole was mixed with 600 ml of n-heptane in areparatory funnel. The lower layer, containing primarily glycerol andsodium levulinate and the sodium salt of the compound of formula (3),wherein R³ is H, was discarded, and the upper layer was filtered througha paper towel. The resulting practically colorless filtrate was strippedof heptane on a rotary evaporator, to yield a clear colorless liquid(385 g) that was analyzed by GC-MS. The liquid was found to containapproximately 24% butyl levulinate and approximately 73% of a 1:1mixture of cis- and trans-isomers of the compound of formula (3),wherein R³ is n-butyl.

The compound (3) was then further purified by distilling out butyllevulinate at a reduced pressure.

Example 19-23

5 grams of a 1.2:1 cis/trans isomer mixture of the compound of formula(3), prepared according to Example 16, wherein R³ is methyl, (96% pure,purified by distillation) were dissolved in 20 ml of each of thefollowing:

(19) absolute ethanol with approximately 0.2% w/w sodium ethoxide,

(20) anhydrous n-butanol with approximately 0.2% w/w sodium n-butoxide,

(21) anhydrous isobutanol with approximately 0.4% sodium isobutoxide,

(22) anhydrous isoamyl alcohol with 0.3% sodium 3-methylbutoxide,

(23) 2-ethylhexyl alcohol with 0.3% sodium 2-ethylhexoxide.

The solutions were stirred for 12 hrs by means of magnetic stirring atroom temperature (26° C.). Progression of the trans-esterificationreaction was monitored by analyzing small aliquots of the reactionmixtures by GC-MS. Formation of esters of formula (3) was observed,wherein R³ is ethyl (Example 19), n-butyl (Example 20), isobutyl(Example 21), isoamyl (Example 22), and 2-ethylhexyl (Example 23). Thereaction did not result in any significant change of the cis/transisomer ratio. After trans-esterification was complete, the reactionmixtures were neutralized by stirring for 8 hours with finely powderedpotassium dihydrogen phosphate, and filtered. Excess alcohol wasdistilled from each sample under reduced pressure, thereby yielding thecompounds of formula (3) in neat form as viscous liquids. The neatcompounds were 94-97% pure (as mixtures of cis/trans isomers).

Example 24

2309 g of the compound of formula (3), R³═CH₃, a 1.05:1 mixture ofcis/trans isomers, purified by distillation under reduced pressure to apurity of about 97%, were fed to a falling film distillation column at arate of about 90 grams per hour. The distillation column was maintainedat 0.5-0.8 millibar vacuum, and the hot finger was maintained at 130° C.780 g of the distillate was collected, and the distillate was found tocontain a 1.55:1 mixture of cis/trans isomers of the compound (3). Theundistilled material that passed through the column (1508 g) was foundto contain a 0.81:1 mixture of cis/trans isomers of the compound offormula (3). The procedure was repeated several times separately withthe mixtures containing either predominantly cis- or predominantlytrans-isomers. After 5 distillations, a sample containing 180 grams of93% pure cis isomer of the compound of formula (3) was obtained, asample containing 226 grams of 88% cis isomer of the compound of formula(3) was obtained, and the remainder of material was divided in severalfractions contained cis/trans isomers in ratios ranging from 82:18 to24:76. The hydroxyesters prepared in this example were practically pure(over 99.5%) and contained no appreciable quantities of glycerol, methyllevulinate, or oligomers comprising the repeating units of formula (6).

Example 25

Sodium methoxide (0.1 g) was dissolved in 51 grams of the compound offormula (3) (R³═CH₃, a 1.05:1 mixture of cis/trans isomers, 99.7% pure),and was placed in a round bottom-flask equipped with magnetic stirring,a vertical air-cooled condenser, an adapter with a side arm, and with aflask to collect distilling methanol. The whole was stirred and heatedto 180-200° C. under nitrogen at atmospheric pressure until distillationof methanol was no longer noticeable (approximately 2 hours). Thereaction mixture rapidly became very viscous. The resulting meltedpolymer (approximately 41 grams) was poured out of the flask into abeaker and was allowed to cool. The polymeric product formed was aviscoelastic thermoplastic ketal-ester polymer comprising repeatingunits of formula (6) with a melting point to 65-70° C.; it had aconsiderable brown discoloration.

Example 26

The polymer synthesis was carried out according to Example 25, except0.08 g of titanium (IV) isopropoxide was used instead of sodiummethoxide, and the reaction was carried out at 220-240° C. for 3 hours.The content of the flask became viscous. A small polymer specimen wasdrawn from the flask, cooled and triturated with t-butyl methyl ether todetermine the presence of starting monomer and any oligomers by GC-MSanalysis. The polymer was practically insoluble in this solvent. Thesolvent extract was found to contain small quantities of compounds (5),(5a), (21), and a trace of the stereoisomers of acyclic oligomers offormula (23):

wherein t is an integer having value from 2 to 4, and R³ is methyl.

Next, a 6 mm vacuum was applied, and the temperature was raised to260-280° C. for about 1 hour. The reaction mixture was allowed to coolto about 140° C. under vacuum, and then about 24 grams of the moltenpolymer was poured out of the flask into a beaker. The resulting productwas a transparent, practically colorless, viscoelastic thermoplasticpolymer comprising repeating units of formula (6). The polymer had amelting point in the range of 70-75° C. The polymer remaining in theflask (15 g) was used in the subsequent examples.

Example 27 Example 27A

The polymer synthesis was carried out according to Example 25, exceptthat 46 g of the compound of formula (3) having a cis/trans isomer ratioof 12:88 was used. The resulting product (36 g) was a transparent,practically colorless, viscoelastic, thermoplastic polymer comprisingrepeating units of formula (6). It had a melting point in the range of85-90° C.

Example 27B

The polymer synthesis was carried out according to Example 25, exceptthat 41 g of the compound of formula (3) having a cis/trans isomer ratioof 92:8. The resulting product (29 g) was a transparent, practicallycolorless, viscoelastic, thermoplastic polymer comprising repeatingunits of formula (6). It had a melting point in the range of 90-95° C.

Example 28

The polymer synthesis was carried out according to Example 25, exceptthat 44 g of the compound of formula (3) having a cis/trans isomer ratioof 52:48, wherein R³ is n-butyl was used. The resulting product (26 g)was a transparent practically colorless viscoelastic thermoplasticpolymer comprising repeating units of formula (6). It had a meltingpoint in the range of 72-77° C.

Example 29

15 g of the polymer prepared in Example 24 were heated in a round bottomflask equipped with a magnetic stirrer, a short-path distillation head,and a receiving flask in an oil bath maintained at 280-300° C. undervacuum using a pump capable of providing an eventual vacuum of 0.08 mm.A distillation of clear transparent liquid was observed, andapproximately 6.2 g of distillate was collected in the receiving flaskcooled by means of an ice bath. The liquid was analyzed by GC-MS and wasfound to contain approximately 62% of the compound of formula (5) andapproximately 34% of the compound of formula (5a).

The compound of formula (5a) had a representative electron ionizationmass-spectrum shown in FIG. 4.

The polymer remaining in the flask was trans-esterified with 20 ml ofmethanol containing 0.2% of sodium methoxide. The methanolic solutionwas analyzed by GC-MS were found to contain a 98% pure sample of thecompound of formula (3), R³═CH₃, with the ratio of cis-/trans-isomers ofapproximately 22:78.

Example 30

130.6 g of polymer repeating units of formula (6) prepared according toconditions described in Example 25 were placed in a round-bottom flaskand 0.3 g of tin (II) 2-ethylhexanoate catalyst were added. The flaskswas equipped with a magnetic stirrer, purged with nitrogen, and washeated to approximately 160° C. to melt the content and dissolve thecatalyst. Vacuum was applied using a pump capable of providing aneventual vacuum of 0.1 mm, and the temperature of the flask wasincreased to approximately 280-300° C. Distillation of a clear, slightlyyellowish liquid was observed, and the distillate (58 g) was collectedin a receiving flask cooled by means of ice bath.

The distillate was cooled and analyzed by GC-MS and was found to containapproximately 57% of the compound of formula (5a) and 40% of thecompound of formula (5a). 46 grams of the resulting mixture of compoundswere separated by distillation under reduced pressure using aKugelrohr-type apparatus providing a fraction containing 22 grams of 96%pure compound of formula (5), and a fraction containing 14 grams of 94%pure compound of formula (5a). Both compounds were obtained ascolorless, practically odorless liquids that solidified to waxy solidson prolonged standing.

The polymer remaining in the flask was trans-esterified with methanolcontaining 0.2% of sodium methoxide. The methanolic solution wasanalyzed by GC-MS and were found to contain a 96% pure the compound offormula (3), R³═CH₃, with the ratio of cis-/trans-isomers ofapproximately 19:81.

Examples 31-32

2 grams of one of the compound of formula (5) or the compound of formula(5a) were each dissolved in 10 mL of methanol containing 0.5% sodiummethoxide, and the solution was stirred for 20 min at room temperature.The resulting solutions were each analyzed by GC-MS and were found tocontain a practically pure (over 99%) cis-isomer of the compound offormula (3b), R³═CH₃.

Example 33

8.6 grams of the compound of formula (5) prepared according to Example30 and 0.03 g of tin (II) 2-ethylhexanoate were heated to 180-220° C.,with stirring under nitrogen. The content of the reaction mixture hadbecome viscous, and after 45 min the reaction was stopped and thecontent of the flask was cooled to room temperature. The resultingproduct was a polymer (8.3 g) comprising repeating units of formula (6)predominantly having a cis configuration. The polymer was a transparent,practically colorless, viscoelastic, thermoplastic polymer, with amelting temperature in the range of 95-100° C.

Examples 34-49

Linear and branched co-polymers comprising repeating units of formula(6) and having two or more ends of the polymer chains terminated withhydroxyl groups were prepared by co-polymerizing 0.1 mol of 99.4% purecompound of formula (3) (R³═CH₃, 51:49 mixture of cis/trans isomers) andone of the following:

(34) 0.011 mol of 1,1,1-tris(hydroxymethyl)ethane,

(35) 0.006 mol of 1,1,1-tris(hydroxymethyl)ethane,

(36) 0.010 mol of 1,1,1-tris(hydroxymethyl)propane,

(37) 0.008 mol of pentaerythritol,

(39) 0.006 mol of glycerol,

(40) 0.002 mol of sorbitol,

(41) 0.003 mol of xylitol,

(42) 0.006 mol of erythritol,

(43) 0.09 mol of 1,4-butane diol,

(44) 0.012 mol of diethylene glycol,

(45) 0.013 mol of 1,3-propanediol,

(46) 0.015 mol of neopentyl glycol,

(47) 0.02 mol of polyethylene glycol of average mol. weight of 1,200 Da,

(48) same as Example 34, plus 0.001 mol of dimethyl adipate,

(49) same as Example 37, plus 0.002 mol of dimethyl terephthalate.

The polymerization reactions were carried out in round bottom flasksequipped with a vertical condenser and a distillation head with side armattached to a receiving flask. All reactions were carried out in thepresence of titanium isopropylate (50 mg) as a catalyst, under nitrogen,by stirring and heating the reaction mixtures in an oil bath maintainedat 220-230° C. for about 3 hours (until distillation of methanolpractically subsided). After that, the bath temperature was reduced toabout 160° C., and the reaction mixtures were stirred for 1 hr undervacuum using a pump capable of providing an eventual vacuum of 6 mm. Theresulting viscous, transparent, practically colorless liquids werecooled to room temperature and stored for subsequent use. The amounts ofpolymers obtained were commensurate with the calculated (theoretical)loss of methanol and no more than an additional 4% weight loss. Theprepared polymers were very viscous liquids at room temperatures.

The resulting polymers were linear co-polymers (Examples 43-47) orbranched co-polymers (Examples 34-42, 48, and 49). The co-polymerscomprising repeating units of formula (6) had two or more ends of thepolymer chains terminated with hydroxyl groups.

Example 50

10.1 grams of polymer comprising repeating units of formula (1),prepared according to Example 9, 3.0 grams of isophorone diisocyanate,and 0.032 grams of dibutyl tin dilaurate were thoroughly mixed togetherin a dry box, using a glass stirring rod, at room temperature. Theviscosity of the resulting solution gradually increased. The reactionmixture was then heated to 130° C. for 30 min, with occasional stirringusing a glass stirring rod, and formation of a viscous, thermoplastic,practically colorless, transparent polymer was observed. The resultingpolymer mass was then cooled to room temperature and solidified. Theresulting polyurethane polymer comprising repeating units of formula (1)was a rigid practically transparent polymer with weak cold flowproperties. At temperatures below 15° C., it was brittle. The polymerhad a melting point in 90-95° C. range and was amenable to meltprocessing and extrusion. No significant deterioration in polymerproperties were observed after 4 melt/cool cycles. The polymer wasinsoluble in water and practically insoluble in the ordinary organicsolvents such as hydrocarbons, ethers, or alcohols.

Example 51

The synthesis was carried out according to Example 50, except that thequantity of isophorone diisocyanate was increased to 1.78 g. Theresulting polymer at room temperature was a viscous transparent,adhesive-like thermoplastic product with good adhesion properties topaper, aluminum foil and low-energy surfaces such as polyethylene andpolypropylene. The polymer was practically insoluble in water.

Example 52

The synthesis of polyurethane polymer was carried out according toExample 50, except that 1.42 g of hexamethylene 1,6-diisocyanate wasused instead of isophorone diisocyanate. The resulting hot polymer wasallowed to cool to room temperature, and to stay in open air for 24hours. The product obtained by such a method was a flexible foam. It wasa fully cured polyurethane polymer comprising repeating units of formula(1), and its properties did not change considerably over time. Thepolyurethane polymer was a practically colorless (off-white) thermosetpolymer, and it could not be successfully re-processed by meltextrusion. The product was practically insoluble in water and inordinary organic solvents such as hydrocarbons, ethers, or alcohols.

Example 53

The synthesis of polyurethane polymer was carried out according toExample 52, except that 1.46 g of tolylene diisocyanate (80:20 isomermixture) was used instead of isophorone diisocyanate. The product was arigid foam. It was a fully cured polyurethane polymer comprisingrepeating units of formula (1), and its properties did not changeconsiderably over time. The polyurethane polymer was a yellowishthermoset polymer, which could not be successfully re-processed by meltextrusion. The product was practically insoluble in water and inordinary organic solvents such as hydrocarbons, ethers, or alcohols.

Example 53

The synthesis of polyurethane polymer was carried out according to theExample 52, except that 2.28 g of 4,4′-methylenebis(phenyl isocyanate)was used instead of tolylene diisocyanate. The product was a rigid foamsimilar in its properties and appearance to the product obtained inExample 52.

Example 54

7.02 grams of the branched hydroxyl terminated polymer preparedaccording to Example 34, 2.03 grams of hexamethylene 1,6-diisocyanate,and 0.03 g of DABCO were thoroughly mixed in a glass vial placed in adry box. A rapid exothermic reaction was observed with the temperatureof the reaction mixture briefly rising to 95-100° C. The content of thereaction mixture rapidly solidified (in less than 4 minutes) to atransparent, slightly brownish product having practically no inclusionsof gas bubbles. The resulting polyurethane polymer comprising fragmentsof formula (6) was cooled down and retrieved from the vial by breakingthe vial. The resulting polyurethane polymer was a highly cross-linked,viscoelastic polymer with memory properties. The resulting polymer waspractically insoluble in water and in ordinary organic solvents such ashydrocarbons, ethers, or alcohols. The product was a thermoset polymerand it could not be re-processed by melt extrusion without deteriorationin polymer properties.

Example 55

The synthesis was carried out according to Example 54, except that the7.08 g of a branched hydroxyl-terminated polymer was used as a startingmaterial, and was prepared according to the Example 48. The resultingpolyurethane was very similar to the polymer obtained in Example 54,except it was a considerably more rigid rubbery polymer.

Example 56

5.8 g of 94% pure decene-1,2-oxide were dissolved in 20.8 g of compoundof formula (3) (R³=methyl, 99.5% purity, 51:49 cis/trans isomermixture). The whole was stirred at room temperature, and 0.08 g of borontrifluoride diethyl etherate was introduced. An exothermic reaction wasobserved. The whole was stirred for 1 hour, and the reaction mixture wasallowed to cool to room temperature. The liquid was analyzed by GC-MSand was found to contain a mixture of isomers of compounds of thecompounds of formula (7), wherein one R⁷ is n-octyl and R⁸ is hydrogen,and R⁷ is hydrogen and R⁸ is n-octyl.

Examples 57-64

The reactions of Examples 56 were repeated using different epoxides, asfollows:

(57) octadecene-1,2-oxide 8.1 g,

(58) hexadecene-1,2-oxide 8.2 g,

(59) tetradecene-1,2-oxide 5.2 g,

(60) dodecene-1,2-oxide 5.6 g,

(61) hexane-1,2-oxide 4.6 g,

(62) butane-1,2-oxide 4.8 g,

(63) propylene-1,2-oxide 3.6 g,

(64) ethylene oxide 2.2 g.

The reactions of Examples 63 and 64 were carried out in pressurizedglass vessels, while the other reactions were carried out at atmosphericpressure. The reaction mixtures were analyzed by GC-MS and were found tocontain compounds of formula (7) with combinations of R⁷ and R⁸corresponding to the chain lengths of the starting epoxides, and theunreacted compound of formula (3).

Examples 65-73

10 g of each of the reaction mixtures obtained in Examples 56-64 wereplaced in round bottom flasks equipped with a magnetic stirrer, acondenser, and a distillation head with an adapter connected to areceiving flask. 0.08 g of titanium (IV) isopropoxide and 0.5 g oftrimethylol propane was added to each of the flasks, and the solutionswere heated under nitrogen using an oil bath set at 200-220° C. Afterdistillation of methanol had practically subsided (about 3 hours), thebath temperature was decreased to 140-160° C., and the stirring wascontinued for 1 hour under vacuum using a pump capable of providing aneventual vacuum of 6 mm. A weight loss was observed that wascommensurate with the theoretical loss of methanol due to a completehydroxyester polymerization, as measured by the weight of the resultingpolymer products. An additional weight loss was also observed,commensurate with presence of inert volatile impurities in the startingepoxides used in Examples 56-64. The resulting polymeric products werecooled to room temperature, purged with nitrogen and stored at roomtemperature. The polymeric products were highly viscous colorless orslightly yellowish transparent or semi-transparent liquids at roomtemperature. The polymeric products were branched hydroxyl-terminatedrandom co-polymers comprising repeating units of formula (6) andrepeating units of formula (24):

The co-polymeric hydroxyl-terminated compounds prepared in this examplewere found to be suitable for making rigid and flexible polyurethanesunder conditions substantially similar to those described in Examples50-55.

Example 74

The reaction was carried out according to Example 56, except that theepoxide used was 10.2 g of a fully epoxidized soybean oil (Vicoflex®7170, Arkema).

Example 75

506.2 grams of a fully epoxidized soybean oil (Vicoflex 7170 brand,

Arkema) were mixed with 1 L of anhydrous methanolic solution containing2.1 g of sodium methoxide, and the resulting mixture was magneticallystirred at room temperature (18° C.) for 6 hours. The progression oftrans-esterification over time was followed by gas chromatography. Afterthe trans-esterification reaction was found to be substantiallycomplete, the reaction mixture was neutralized by the addition of 12.8grams of finely powdered anhydrous potassium dihydrogen phosphate,followed by an additional stirring overnight (12 hours). The resultingmixture was filtered and the methanol was evaporated under reducedpressure using a rotary evaporator with a water bath set to 40° C. Theresulting oil was dissolved in 1 L of hexanes, filtered, and the hexaneswere removed under reduced pressure using a rotary evaporator. A cleartransparent product with weak oily odor (485 g) was thereby obtained andwas analyzed by GC-MS. When using a TIC integration method, the oil wasfound to contain approximately 9% methyl hexadecanoate, 5% methyloctadecanoate, 42% methyl 9,10-epoxy-9-octadecenoate, 40% isomers ofmethyl 9,10,-12,13-bisepoxy-9,12-octadecenoate, and small quantities ofthe esters of other saturated and epoxidized unsaturated fatty acids.

Example 76

The synthesis was carried out according to Example 56, except that theepoxide used was 8.2 g of the mixture of epoxidized unsaturated fattyacid esters prepared according to Example 75. The reaction mixture wasanalyzed by GC-MS and was found to comprise reaction products havingformulae (9), (10a), (10b), unreacted the compound of formula (3), andthe methyl esters of hexadecanoic and octadecanoic acid in quantitiescommensurate to their amounts in the starting material.

Example 77

0.4 g of the reaction product mixture obtained in Example 74 wastrans-esterified by dissolving it in 4 ml of methanol containing 0.5%sodium methoxide, and the whole was stirred for 4 hr at roomtemperature. The reaction mixture was neutralized by stirring withpowdered 0.32 g of anhydrous potassium dihydrogen phosphate for 1 hour,filtered and analyzed by GC-MS. The product mixture was found to bepractically identical to the that obtained in Example 76.

Examples 78-79

10 g of one of the reaction product mixtures obtained in Examples 74 or76 were treated according to the conditions of Examples 65-73. Theresulting product was a cross-liked co-polymer containing repeatingunits of formula (1) and fragments derived from the modified fatty acidester derivatives of formulae (9), (10a), and (10b). The resultingpolymers were rubbery transparent thermoset elastomers with moderateyellow-orange discoloration. The polymers were practically insoluble inwater, acetone, methylethylketone, hydrocarbons, ethers, and esters.

Approximately 0.2 g of each of the polymers obtained in this Examplewere de-polymerized by treatment according to the conditions describedin Example 77. The GC-MS analysis of the resulting mixture ofde-polymerized products showed that the mixture had a substantiallysimilar composition to that observed in Examples 76 and 77, with theexception of the content of the methyl esters of hexadecanoic andoctadecanoic acid, which was less than 2%.

Example 80

(a) The reaction was carried out according to Example 74 on a 5.4 foldscale. Powdered sodium fluoride (1 g) was added to neutralize thecatalyst, and the whole was stirred for 18 hours at room temperature andfiltered. The excess of compound (3) distilled out at reduced pressure,to give approximately 61 g of a modified triglyceride adduct havingapproximately 4.6 hydroxyl groups per molecule of triglyceride (afree-flowing transparent viscous liquid with moderate yellow-orangediscoloration).

(b) 20.1 grams of this product were thoroughly mixed with 3.2 grams ofhexamethylene-1,6-diisocyanate and 50 mg of dibutyl tin dilaurate, andthe mixture was cured for 1 hour at 105° C. The resulting polyurethanepolymer was a closed-cell, flexible, soft, fully cured yellow foam(thermoset polymer).

Example 81

(a) The modified triglyceride synthesis was carried out according toExample 80, except that addition of sodium fluoride was omitted. Theresulting product was a partially cross-linked adduct with molecularweight of approximately 4500 Da.

(b) 19.3 grams of this product was thoroughly mixed with 1.3 grams ofhexamethylene-1,6-diisocyanate and 50 mg of dibutyl tin dilaurate, andthe mixture was cured for 1 hour at 105° C. The resulting polyurethanepolymer was a closed-cell, flexible, soft, yellow, fully-cured foam (athermoset polymer) with properties very similar to those obtained inExample 80.

Examples 82-83

The polyurethane foams obtained in Examples 80 and 81 were depolymerizedaccording to Example 77. The resulting product mixture was found to besubstantially similar to those observed in Examples 76 and 77, with theexception of the presence of the compound of formula (3) which waspresent in the products of the present Examples only in small quantities(2-3)%.

Example 84

5.1 g of branched hydroxyl-terminated co-polymer prepared according toExample 36 were dissolved in 8 g of tolylene diisocyanate (80:20 isomermixture), and 0.02 g of dibutyl tin dilaurate was added. The whole washeated with vigorous stirring to 85-90° C. under nitrogen, and theexcess tolylene diisocyanate was evaporated under reduced pressure. Theresulting polymeric product (7.3 g) is an isocyanate-terminated branchedpolymer (a polyisocyanate) comprising repeating units of formula (6).The product was a viscous yellowish transparent liquid.

Examples 85-86

The synthesis of polyurethane foams was carried out according toExamples 80 and 81, except that the synthesis was carried out with 2.6 gof the polyisocyanate polymer obtained in Example 84, instead ofhexamethylene diisocyanate. The resulting polyurethane foams weresimilar in their properties to the foams obtained in Examples 80 and 81,except they were more rigid.

Examples 87-88

One of the following:

(Example 87) 15.6 grams of the modified triglyceride prepared accordingto Example 80(a), or

(Example 88) 15.1 grams of the fatty ester adduct prepared according toExample 76, followed by distillation of excess compound of formula (3),was refluxed in 100 ml of methanol containing 0.05% of p-toluenesulfonic acid, to effect a trans-esterification reaction. The solutionwas monitored by GC-MS for appearance of methyl levulinate and methyl4,4-dimethoxypentanoate. After the reaction was deemed complete (about 6hours), both solutions were neutralized with 100 mg of sodiumbicarbonate, filtered, and stripped of methanol under reduced pressure,to give a mixture of 1-glyceryl ether modified fatty acid esters (asoily liquids).

The glyceryl ether adducts were then mixed with 0.2 g of titaniumisopropylate and heated to 95-100° C. under 6 mm vacuum, with stirring,until the content had become viscous (about 3 hrs), to give highlybranched or crosslinked polyester-polyether compounds having molecularweights of approximately 3,500 Da.

5 gram portions of each of the resulting cross-linked polymers weremixed with 0.5 ml of methylethylketone and 0.3 grams of tolylenediisocyanate, and 0.01 g of dibutyl tin dilaurate was added. Themixtures were each stirred thoroughly and placed in a vacuum oven set at100° C., incubated at atmospheric pressure for about 15 min, and then avacuum was applied using a pump capable of providing an eventual 6 mmvacuum. The reaction mixtures were then left at 6 mm vacuum at 100° C.for 2 hrs, and then cooled down and brought to atmospheric pressure. Theresulting polyurethanes were propellant-expanded, semi-rigid foams withdensity of about 0.22 g per cm³.

Example 89

30 grams of a cellulose acetate polymer with 39.8% acetyl content andM_(n) ca. 30,000 (Sigma-Aldrich Cat. No. 18,095-5) were mixed with 50grams of the compound of formula (3) (R³=methyl, 99.5% purity, 51/49cis/trans mixture of isomers), and 0.2 grams of titanium isopropylatewas added. The whole was stirred and heated to 160-180° C. for 6 hoursunder nitrogen at atmospheric pressure, and then under 1 nun vacuum, toremove any unreacted compound of formula (3). The resulting polymer (42g) was a water-insoluble polyhydroxylated graft polymer with a cellulosepolymer backbone and pendant groups comprising repeating units offormula (6). The polymer was a transparent, agar-like gel practicallyinsoluble in water.

Example 90

Reaction product mixtures comprising epoxide adducts prepared inExamples 56-67 and 76 were each stripped of the excess of hydroxyestercompound of formula (3) by distillation under reduced pressure. 3.2-3.3grams of each of the resulting products were saponified with 10 ml of 1Msodium hydroxide by vigorous stirring for 2 hrs at 85-90° C. Excess basewas neutralized by titration with aqueous hydrochloric acid to pH 8-9,and the solutions were diluted with water to a final volume of 15 ml.The solutions of sodium salts of the saponified adducts of the compoundof formula (3) with the various epoxides were then examined for theirsurfactant properties using a 1:1 hexane-water emulsion forming test,and by evaluating the stability of such emulsions in the presence and inthe absence of calcium or magnesium ions (final concentrations of 1%CaCl₂ or 1% MgCl₂ were used in the emulsion tests). In addition, thesaponified compounds were also tested in hexane-water emulsion tests atpH 3, and non-saponified compounds were also tested for their surfactantproperties at pH 7. All emulsion tests were performed at roomtemperature.

Salts of the compounds obtained by saponification of the epoxide adductsof Example 76 and of Examples 56-60 were found to be good surfactantscapable of forming and supporting stable hexane-water emulsions, andtheir surfactant properties were not adversely affected by the presenceof calcium or magnesium ions. At acidic pH, the properties of thecompounds Example 76 and Examples 56-60 were also found satisfactory.Non-saponified compounds of Examples 56-60 were found to be“water-in-oil” type emulsifiers.

Example 91

Plasticized polymer compositions and various blends of the polymericcompounds comprising fragment of formula (6) were prepared by a meltmixing and extrusion method, using one of the following polymers:

-   -   (a) PVC, poly(vinyl chloride) powder (average M_(n) ca. 55,000,        average M_(w) 97,000, inherent viscosity 0.92, relative        viscosity 2.23, supplier Sigma-Aldrich Company, Cat. No.        34,677-2),    -   (b) PHB, poly(3-hydroxybutyrate), (natural origin, Tm 172° C.,        supplied by Sigma-Aldrich Cat. No. 36,350-2),    -   (c) AC, a cellulose acetate polymer with 39.8% acetyl content        and M_(n) ca. 30,000 (Sigma-Aldrich Cat. No. 18,095-5),    -   (d) PLA (L-polylactide, inherent viscosity 0.90-1.20, Average        M_(w) 10,000-150,000, Tg 48.5° C., Supplied by Sigma-Aldrich        Company, Cat. No. 53, 117-0).

Plasticized and blended compositions were prepared at a 5 g scale bypre-mixing cold ingredients. Each of the resulting mixtures wereindividually fed into a pre-cleaned, miniature twin-screw mixer-extruderchamber of a Daca Microcompounder (Daca Instruments) under nitrogen,with the mixing chamber heated to 5-10° C. above the melting temperatureof the component with the highest melting point, and the motor speed wasset to 100 rpm. The samples were mixed for about 5 minutes, and theresulting melt was then extruded out of the mixing chamber as a flexiblerod (diameter 3 mm), which was immediately cooled to room temperature inambient air.

The plasticizers and the polymer blends were tested at severalconcentrations including at least one compound of the present disclosureat 5, 10, 25, and 50% by weight of the resulting composition.

Glass transition temperature data (by differential scanningcalorimetry), and plasticizer exudation data were collected usingplasticized specimens cut from the extruded rods that have shown asatisfactory compatibility and acceptably low levels of exudation of thepolymer composition components.

Polymer blends comprising one of PHB, PLA, and AC were found compatiblein a broad concentration range with the polymeric compounds prepared inExamples 26-28, 33, 50, 51, 65-73, 89. Such blends were significantlyplasticized, as displayed by significantly lowered glass transitionpoints in comparison with non-plasticized PHB, PLA, and AC. The samecompounds were also found to have limited compatibility with PVC (up to10%), reducing the glass transition point of the plasticized PVC byabout 15-30° C.

PHB, PLA, AC polymers were also successfully plasticized with compoundsprepared in Examples 34-49, as well as with the compound of formula (5),(5a), and with the compound of formula (3) and (4), except cases whereinR³ was H.

Among the compounds tested, the PVC polymer was most successfullyplasticized with compounds prepared according to Examples 80(a), 81(a),57-61, 76 (after removal of excess of compound 3 by distillation),compounds of formula 5a, and compounds of formula (3) and (4), whereinboth R³ and R⁶ were C₄-C₈ linear or branched alkyls.

Example 92

2.1 grams of the polyurethane polymer comprising repeating units offormula (6) obtained in Example 52 were stirred at room temperature in15 ml of absolute ethanol containing 0.5% of sodium ethoxide untilcomplete dissolution was observed (about 5 hours). The resultingsolution was neutralized by stirring for 1 hour with powdered potassiumdihydrogen phosphate, and the ethanol was distilled out under reducedpressure. The residue was dissolved in tert-butyl methyl ether andfiltered. The filtrate was analyzed by GC-MS and was found to contain95% pure compound of formula (3) (R³=Et, cis/trans isomer mixture). Thetert-butyl methyl ether was evaporated under reduced pressure, yieldingabout 1.52 g of the neat compound of formula (3).

Example 93

The reaction was carried out according to Example 92, except thepolyurethane polymer was 2.3 grams of the polymer prepared in Example54, and n-butanol with 0.3% of sodium n-butoxide was used. The resultingneat monomer (1.78 g) was a 97% pure compound of formula (3) (R³=n-Bu,cis/trans isomer mixture).

A number of embodiments of the disclosure have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the spirit and scope of the disclosure.Accordingly, other embodiments are within the scope of the followingclaims.

1. A method of making a polyurethane polymer, the method comprising:providing one or more isocyanate compounds having two or more isocyanategroups; providing a polyol polymer comprising i) a unit of formula (6):

wherein q is an integer and ii) two or more hydroxyl groups present onaverage per representative polymer molecule; and contacting the one ormore isocyanate compounds having two or more isocyanate groups with thepolyol polymer under reaction conditions effective to form thepolyurethane polymer, wherein the resulting polyurethane polymercomprises one or more units of formula (6) per representativepolyurethane polymer molecule.
 2. The method of claim 1, wherein thepolyol polymer has an average molecular weight in excess of 500 Da. 3.The method of claim 1, wherein the polyol polymer has an averagemolecular weight in excess of 1000 Da.
 4. The method of claim 1, whereinthe polyol polymer is a linear polymer.
 5. The -linked, or star-methodof claim 1, wherein the polyol polymer is a branched, or star-shapedpolymer.
 6. The method of claim 1, wherein the polyol polymer is across-linked polymer.
 7. The method of claim 1, wherein the polyolpolymer is made by the method comprising contacting a monomer of formula(3):

wherein R³ is a linear, branched, or cyclic alkyl or alkenyl, aryl,aralkyl, or alkyloxyalkyl, formula (4):

wherein R³ is a linear, branched, or cyclic alkyl or alkenyl, aryl,aralkyl, or alkyloxyalkyl, and R⁶ is hydrogen, or is a linear, branched,or cyclic alkyl or alkenyl, aryl, aralkyl, alkyloxyalkyl, or oxoalkyl,formula (5):

or formula 5(a):

or combinations thereof with a sufficient amount of a co-polymerpolyhydric alcohol having two or more hydroxyl groups under reactionconditions effective to form the polyol polymer.
 8. The method of claim1, wherein the reaction conditions comprise the use of a catalyst. 9.The method of claim 8, wherein the catalyst is dibutyl tin dilaurate,1,4-diazabicyclo[2.2.2]octane, or combinations thereof.
 10. The methodof claim 1, wherein the reaction conditions comprise a temperaturebetween 30 and 160° C.
 11. The method of claim 1, wherein the reactionconditions comprise substantially anhydrous conditions.
 12. The methodof claim 1, wherein the isocyanate is isophorone diisocyanate, tolylenediisocyanate, hexamethylene 1,6-diisocyanate, 4,4′-methylenebis(phenylisocyanate), or combinations thereof.
 13. A polyurethane polymercomposition comprising a polyol polymer residue, wherein the residuecomprises a unit of formula (6):

wherein q is an integer.
 14. The polyurethane polymer of claim 13,wherein the polymer is a solid.
 15. The polyurethane polymer of claim13, wherein the polymer is a viscous liquid.
 16. The polyurethanepolymer of claim 13, wherein the polymer is rigid.
 17. The polyurethanepolymer of claim 16, wherein the polymer is a foam.
 18. The polyurethanepolymer of claim 13, wherein the polymer is flexible.
 19. Thepolyurethane polymer of claim 18, wherein the polymer is a foam.
 20. Thepolyurethane polymer of claim 13, wherein the polymer is a thermoset.21. The polyurethane polymer of claim 13, wherein the polymer is athermoplastic.
 22. An article comprising a polyurethane polymercomposition comprising a unit of formula (6):

wherein q is an integer.
 23. The article of claim 20, further comprisingat least one of an organic or inorganic filler, a pigment, a stabilizer,an anti-oxidant, a lubricant, or combinations thereof.
 24. The articleof claim 20, wherein the article is a cast article.
 25. The article ofclaim 20, wherein the article is an extruded article.
 26. The article ofclaim 20, wherein the article is a shaped article.